Varec 4532, Installation And Operation Manual

Page 1: ...tree Corners East Norcross Atlanta GA 30092 USA Tel 1 770 447 9202 Fax 1 770 662 8939 www varec com IOM019NVAE0208 4532 Average Temperature Sensor and Converter Installation and Operations Manual For software version V1 45 ...

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Page 3: ...eans 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 recognizes all other trademarks Trademarks of other products mentioned in this document are held by the companies producing them Varec is a registered trademark of Varec Inc a wholl...

Page 4: ... event that a court holds that this document created some new warranties Seller s liability shall be limited to repair or replacement under the standard warranty clause In no case shall the Seller s liability exceed that stated as Limitations of Remedy in the contract between the Seller and Buyer Terms of Use The information provided in this document is provided as is without warranty of any kind ...

Page 5: ...t 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 Follow all precautions and warning noted herein when installing operating or performing maintenance on this equipment ...

Page 6: ...Average Temperature Water Bottom Sensor and Converter 4 Installation and Operations Manual ...

Page 7: ...ty 3 2 3 1 Hazardous area 3 2 3 2 Power supply 4 2 3 3 Grounding 4 2 3 4 Wiring 4 2 4 Return 4 2 5 Disposal 4 2 6 Notes on safety conventions and symbols 5 3 Identification 7 3 1 Device designation 7 3 1 1 Nameplate 7 3 2 Scope of delivery 7 3 3 CE marks declaration of conformity 8 4 Installation 9 4 1 Design dimensions 9 4 2 Unpacking 10 4 3 Flexible tube 10 4 4 Installation Instructions 11 4 5 S...

Page 8: ...he 4590 TSM 28 7 3 Device set up 6000 Series Servo Tank Gauge 28 7 3 1 Preparation of 6000 Series Servo Tank Gauge 28 7 3 2 4532 ATC configuration on 6000 Series Servo Tank Gauge 28 8 Operation and Description of Instrument Function 31 8 0 1 HART Device designation 31 8 0 2 Device Data 31 8 1 Temperature measurement 31 8 1 1 Primary values VH00 VH09 31 8 1 2 Element Temperature 1 VH10 VH15 32 8 1 ...

Page 9: ...1 System error messages 47 10 2 Spare parts 48 11 Accessories 49 11 1 Anchor weight Tall profile 49 11 2 Anchor weight Low profile 49 11 3 Wire hook Top anchor 50 12 Technical data 51 A Order Structure 53 B Declaration of Contamination Form 55 Index 57 ...

Page 10: ...Contents Average Temperature Water Bottom Sensor and Converter 4 Installation and Operations Manual ...

Page 11: ...en into account in order to avoid any harmful conditions The installation method depends on the type of 4532 ATC Refer to Chapter 4 Installation Step 2 Wiring to the host instruments 4590 TSM Wiring material and conditions must be in accordance with intrinsically safe standards One end normally on the host instrument side of the shield twisted pair of cables must be grounded at the terminal connec...

Page 12: ...th 7500 Series Radar 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 Temperature ToF Tool FieldTool Package Commubox FXA191 195 HART 2 wire 2 wire Power DC Ex i Ex i Ex i Ex d 4590 TSM Level Interface Density Bottom Temperature HART 2 wire Power AC DC HART 2 wire ...

Page 13: ... proper operation of the product 2 2 2 Use in hazardous areas When using the product in the first or second class hazard location Zone 1 or Zone 2 be sure to use an intrinsically safe or pressure and explosion proof apparatus Take the utmost care during the installation wiring and piping of such apparatus to ensure the safety of the system For safety reasons maintenance or repairs on the product w...

Page 14: ... pliance could void the user s authority to operate the equipment 2 4 Return The following procedures must be carried out before the instruments 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 safety data sheet as per EN 91 ...

Page 15: ...plosion hazardous areas Symbol used in drawings to indicate explosion hazardous areas Devices located in and wiring entering areas with the designation explosion hazardous areas must conform to 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 ...

Page 16: ...Safety instructions Average Temperature Water Bottom Sensor and Converter 6 Installation and Operations Manual ...

Page 17: ...F Li 48μH NEMA 4X WARNING Do not modify parts and circuits of this instrument Install per control drawing Ex461 869 IS Cl I Div 1 Gp C D Cl I Zone0 AEx ia IIBT NI Cl I Div 2 Gp C D Varec Inc 5834 Peachtree Corners East Norcross Atlanta Georgia 30092 USA 16 04532AT Rev B WARNING Do not modify parts and circuits of this instrument Made in Japan 4532 Series Temperature Device Ambient Temperature 40 C...

Page 18: ...nd 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 The instrument described in this manual thus complies with the statutory requirements of the EG directives Varec confirms the successful testing of the inst...

Page 19: ...Varec Inc 9 4532 Installation 4 Installation 4 1 Design dimensions Figure 4 1 4532 ATC dimensions Ф10 Ф26 Bottom hook 215 mm Flexible tube depends on the tank height 142 5 mm ...

Page 20: ...ommended procedure below 4 3 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 Figure 4 2 Flexible tube Note If a flexible tube is bent with a radius of curvature less than 300 mm 11 8 the flex ible tube or the measuring element may be seriously damaged or broken Recommended procedure Incorrect procedure Min 1m 39 37...

Page 21: ...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 5 Special conditions for safe use To exclude ignition sources due to sparks caused by impact or friction even in the event of rare incidents do not subject the temperature sensor tube to environmental stress such as impact from moving p...

Page 22: ...Installation Average Temperature Water Bottom Sensor and Converter 12 Installation and Operations Manual ...

Page 23: ...C at a minimum of 500 mm 19 67 away from the tank shell This will ensure that the measurement is not influenced by changes in ambient temperature 3 The procedure for mounting the 4532 ATC on a tank depends on the type of tank Here we shall explain the procedures for a fixed roof tank and for a floating roof tank In any case the flexible tube head is mounted on the tank top as show in fig 5 The mou...

Page 24: ...e hook and a top anchor Figure 5 2 Top anchor application 1 Insert a gasket and lower the flexible tube from the nozzle on the tank top Caution The flexible tube must be lowered carefully without bending too much and scratching at the inner edge of the nozzle hole 2 Rotate the 4532 ATC so that you can set up the cabling in the most convenient way 3 Straighten the tensioning wire fix the wire end t...

Page 25: ...nk top using bolts Note Please keep the compression of the spring at 35 to 37 mm 1 38 to 1 47 If you compress the spring over 35 to 37 mm it may cause damage to the sensor 7 Draw the end of the tensioning wire as much as possible by hand and foot see Figure 5 4 8 Bend the wire and fix it using the nut 9 Cut the excess wire 10 Screw the nut to compress down the spring of the top anchor 35 to 37 mm ...

Page 26: ...e nozzle hole 1 Insert a gasket and lower the flexible tube into the inlet of the stilling well 2 Rotate the 4532 ATC so that you can set up the cable in the most convenient way 3 Fix the mounting flange of the 4532 ATC to the nozzle on the tank top using bolts Electrical compartment Cable entry as specified Flange Flexible tube approx 500 mm From tank bottom to element position 1 Clearance below ...

Page 27: ...wer the flexible tube from the nozzle on the tank top 2 Rotate the 4532 ATC so that you can set up the cabling in the most convenient way 3 Tighten the tensioning wire between the lower end of the flexible tube and the anchor weight 4 Wrap the tensioning wire twice around a hole on the bottom hook tighten it and wrap a provided wire around it see Figure 5 7 on page 16 5 Fix the mounting flange of ...

Page 28: ...ng 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: ...ng coil type 5 3 1 Top anchor method The flexible tube is installed in a fixed pipe and stabilized by a top anchor The 6000 Series Servo Tank Gauge and 4532 ATC can be mounted in the same fixed pipe Figure 5 8 Top anchor application The installation procedure is the same as for mounting on a fixed roof tank using the top anchor Top anchor Flexible tube Element position 1 Bottom element Ø26mm 1 02 ...

Page 30: ... the fixed pipe Figure 5 9 Thermo well application The installation procedure is the same as for mounting on a fixed roof tank using the thermo well Flexible tube Element position 1 Bottom element Ø26mm 1 02 Clearance below bottom hook 500mm 19 69 400mm 15 75 Gauge plate Gas hole Electrical compartment Cable entry as specified Flange Thermo well Min Ø2 depend on sch Fixed pipe ...

Page 31: ...e inner edge of the nozzle hole 1 Set the guide ring to the floating roof 2 Insert a gasket and lower the flexible tube from the nozzle on the tank top 3 Rotate the 4532 ATC so that you can set up the cabling in the most convenient way 4 Tighten the tensioning wire between the lower end of the flexible tube and the anchor weight Wind the tensioning wire twice around each of the hitches and wrap a ...

Page 32: ...Mounting Average Temperature Water Bottom Sensor and Converter 22 Installation and Operations Manual ...

Page 33: ...able the 4532 ATC to be a terminal junction for HART multi drop instruments Z1 Z1 H2 H2 H2 H2 H1 H1 H1 H1 Z2 Z2 Z3 Z3 AR1 AR1 H2 H2 H2 H2 H1 H1 H1 H1 Ground terminal Screened twisted pair or steel armored wire to 4590 TSM terminal 24 26 or 28 terminal 25 27 or 29 or to 6000 STG teminal 24 terminal 25 Note Metal cable gland only Shield of HART communication line must be grounded Temp data I S HART ...

Page 34: ...0 TSM i s terminal Figure 6 3 4590 TSM terminal 4 20 mA 4 20 mA Channel 1 Channel 2 Port_A Port_A IS HART or _ _ A B b 22 23 24 25 26 _ COM HOIST STOP Operation contact input 20 21 16 19 18 17 Alarm contact Alarm contact Alarm contact _ _ _ 10 15 14 13 12 11 Alarm contact _ Port_B Port_B Non IS HART to NRF or others _ 9 8 7 6 5 4 Power supply AC 85 264V 50 60Hz or DC 20 62V AC20 55V 2 3 1 G N L L ...

Page 35: ...2 ATC must be grounded to the tank potential before communication and power connections are made The connections from ground terminal of the 4532 ATC to the tank ground must be made before any other wiring connections are made All grounding must be compliant with local and company regulations and checked before the equipment is commissioned Figure 6 4 The 4532 ATC Grounding Z1 Z1 H2 H2 H2 H2 H1 H1...

Page 36: ...Wiring Average Temperature Water Bottom Sensor and Converter 26 Installation and Operations Manual ...

Page 37: ... Communicator or the Varec ToF field service tool to set a specific HART address 20 Measurement function 0 Converter only 1 Temperature converter These four basic data are available as standard Average liquid temperature Average gas phase temperature Level entered liquid level at VH02 measured distance Device status 7 2 Device set up 4590 TSM Connect the loop powered HART communication cable from ...

Page 38: ... connection via the multi drop HART loop GVH362 NMT connection Average Temp must be selected in order to configure the 4532 ATC Caution To change this parameter an access code is required Please refer to the 6000 Series Servo Tank Gauge operation manual for further information 7 3 2 4532 ATC configuration on 6000 Series Servo Tank Gauge Most required 4532 ATC parameters can be configured on G4 Tem...

Page 39: ...450 459 Temp No 1 10 The temperature reading value from each inserted element in the probe The reading element temperature above 11 16 must be selected at the GVH470 Select Point then the read value at the GVH473 Element Temp GVH460 49 Element Position No 11 16 not available with 4532 ATC GVH470 Select Point A matrix to select the desired element data on GVH471 Zero Adjust GVH473 Element Temp and ...

Page 40: ...Operating Average Temperature Water Bottom Sensor and Converter 30 Installation and Operations Manual ...

Page 41: ...d only Range 200 C 240 C Note Display of measured liquid phase average temperature Liquid level input must be provided by the 7200 or 7500 Series Radar Tank Gauge via 4590 TSM or 6000 Series Servo Tank Gauge in order to calculate true liquid average temperature VH01 Gas Temp Item type read only Range 200 C 240 C Display of measured gas vapor phase average temperature Note Display of measured gas v...

Page 42: ... value in the temperature probe The reading value of the reference resistor and its deviation are continuously monitored during operation to prevent an incorrect calculation Indicated tolerance should be within 0 15 C 0 27 F depending on element characteristics 8 1 2 Element Temperature 1 VH10 VH15 VH16 19 used only in 4539 ATC539 VH10 19 Temperature 1 10 Item type read only Range 200 C 240 C Disp...

Page 43: ...factor to compensate for unequal volume distribution example liquid temperature Formula T1 V1 T2 V2 T3 V3 V1 V2 V3 Average temperature Note V of additional volume factors and related parameters are determined at VH53 54 and 55 Element 1 3 5 C T1 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 Element 5 4 5 C T5 Element 4 4 0 C T4 Element 3 2 0 C T3 El...

Page 44: ...otal number of element submerged VH28 Lower Limit Item type read and write Default value 20 5 C RANGE 999 9 C 999 9 C Low limit temperature alarm setpoint Element 1 3 5 C T1 Element 5 4 5 C T5 Element 4 4 0 C T4 Element 3 2 0 C T3 Element 2 3 0 C T2 2 0 C V volume factor 3 5 C 3 0 C 2 0 C 2 0 C 2 0 C 3 0 C 3 0 C 3 5 C Liquid average temperature T1 T2 T3 3 25 5 C Pt100 element 1 25 0 C T1 Pt100 ele...

Page 45: ...rmed when element spacing Even is selected at VH85 8 1 5 Element Position 2 VH40 VH45 are not available in 4532 ATC VH46 Hysteresis Width Item type read and write Default 10mm Range 0mm 99999mm Element switching point hysteresis The hysterisis is an offset value added to the liquid level when the level is increasing and subtracted from the liquid level when the level is decreasing This setting ens...

Page 46: ... and write Default 300mm Range 0mm 99999mm A function to exclude element s from the liquid phase average temperature calculation when the uncovered element s is are within the entered value from the liquid level Liquid Level Liquid phase Gas phase VH48 GAS Offset 300mm default Temp element within this range will be excluded from Gas average calculation To 4532 ATC Electric housing Temperature Elem...

Page 47: ...cified element for advanced average temperature calculation For details refer to the description of VH26 Select Average Method on page 30 8 1 7 WB Adjustment and Operation Power VH60 VH69 VH67 Common Voltage Item type read only Range 0 255 0 3V A display of temperature element line both signal and common running voltage The detected voltage across the common line between 0 3V is converted to a ran...

Page 48: ...rs of the selected element can be shown in VH71 Zero Adjust VH73 Temperature X VH74 Position X VH75 Resistance X VH76 Resistance Adj VH71 Zero Adjust Item type read and write Default 0 Range 1000 0 1000 0 Zero adjustment of the individual element selected at VH70 This value can be adjusted when the measured temperature of the selected element has a minor offset value as compared to a precision ref...

Page 49: ...cified element resistance at VH70 Minor resistance adjustment can be applied on the reading value Note e g If selected element 5 indicates 100 3 Ohm and reference precision resistor indicates 100 0 Ohm at the same environmental condition then set 0 3 in this matrix 5 element now has constant artificial 0 3 C offset resistance based on raw measurement VH77 Element Type Item type select Selection Pt...

Page 50: ...t Function Average 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: ...nt open 14 6 element short 23 0 element over range 24 Memory defect ROM 29 Element exposed liquid level below 1 element position 30 undetermined 31 undetermined 41 Memory defect RAM 42 Memory defect EEROM VH81 Temperature Unit Item type select Default C Selection C F K Selection of temperature display unit Based on universal HART setting C HART code 32 F HART code 33 and K HART code 35 are availab...

Page 52: ...election of level display unit It applies to liquid level display on VH02 Liquid Level Level units are coded based on universal HART setting ft HART code 44 m HART code 45 inch HART code 47 mm HART code 49 VH85 Kind of Interval Item type select Default Even Interval Selection Even Interval always Even for 4532 ATC Selection of element interval depending on spacing layout Caution Do not change this...

Page 53: ...has a short circuit Method of display can be configured at VH92 Error Display Select VH89 Open Error Item type read write Default 359 9 Range 49 5 359 5 Error element displayed when any element has an open circuit Method of display can be configured at VH92 Error Display Select 8 1 9 Device setting 2 VH90 VH99 VH90 Device ID Number Item type read and write Default 0 Range 0 16777214 In order to di...

Page 54: ... on host gauge default screen and may transmit to upper receiver as well VH94 Polling Address Item type read and write Default 2 Range 1 15 Polling address for HART communication VH95 Manufacture ID Item type read only Default 17 The manufacturer ID for Endress Hauser instrumentation VH96 Software Version Item type read only A display of installed software version VH97 Hardware Version Item type r...

Page 55: ...ers on later pages Please contact Varec Service for further information on service and spare parts 9 3 Repairs to Ex approved devices When carrying out repairs to Ex approved devices please note the following Repairs to Ex approved devices may only be carried out by trained personnel or by Varec Service Comply with the prevailing standards national Ex area regulations safety instructions XA and ce...

Page 56: ...e 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 GVH Contents 443 Level Data Selection 460 469 Element Position No 1 9 470 to select elements 10 15 474 to adjust position of element selected at GVH 470 482 Total No elements 485 Kind of Interval 486 Bo...

Page 57: ...gage connector from the module then check continuity on pointed signal cable 1 6 23 0 element over range When reference 0 element has more than 1 1 C deviation from 0 C Check power supply voltage on 4532 ATC HART terminal H and H 24 Memory defect ROM When a defect was discovered during whole memory parameter check Cyclic data comparison between previous check sum to current one Replace main CPU bo...

Page 58: ...e 4532 ATC are shown with their order numbers in the diagram below For more information on service and spare parts contact Varec Figure 10 1 Spare Parts Terminal EMC filter assy 58020200 017802 0008 Cover El housing M88 long type O ring EPDM 88 d3 Module assembly Temp V187 58020200 017802 0008 Cover T3 M77 O ring EPDM 73 d3 70106024 017803 0043 70106026 017803 0044 017803 0044 70106026 017803 0043...

Page 59: ...able Consult your Varec representative for further details 11 2 Anchor weight Low profile The low profile anchor weight is a version for an existing tank installation with a small nozzle opening for converter and temperature version Figure 11 2 Low profile anchor weight dimension 180mm 7 09 222mm 8 74 Material 42mm 1 65 Weight SS400 mild carbon steel Ring SS400 mild carbon steel Weight approx 16kg...

Page 60: ...application and installation variable type of wire size material and special coatings are available Please consult your Varec representative for further details Figure 11 4 Top anchor dimension Note The standard process connection of the Top anchor is NPT1 threaded connection Different thread size material and specification are available Flange type connec tion is also available 9mm 0 35 21mm 0 83...

Page 61: ...lti drop HART loop connection Signal on alarm Error information can be accessed via the following interfaces and transmitted digital protocol refer to the operation manuals on following instruments Tank Side monitor 4590 TSM 6000 Series Servo Tank Gauge Auxiliary energy Load HART Minimum load for HART communication 250 W Cable entry see technical document Supply voltage 16 30VDC on multi drop HART...

Page 62: ...Technical data Average Temperature Water Bottom Sensor and Converter 52 Installation and Operations Manual ...

Page 63: ...00 2 m min 4 500 mm max 6 500 mm 042 mm 4x Pt100 2 m min 6 500 mm max 8 500 mm 052 mm 5x Pt100 2 m min 8 500 mm max 10 500 mm 062 mm 6x Pt100 2 m min10 500 mm max 12 500 mm 023 mm 2x Pt100 3 m min 3 500 mm max 6 500 mm 033 mm 3x Pt100 3 m min 6 500 mm max 9 500 mm 043 mm 4x Pt100 3 m min 9 500 mm max 12 500 mm 053 mm 5x Pt100 3 m min 12 500 mm max 15 500 mm 063 mm 6x Pt100 3 m min 15 500 mm max 18...

Page 64: ...Order Structure Average Temperature Water Bottom Sensor and Converter 54 Installation and Operations Manual ...

Page 65: ...andling instructions if appropriate Warnings for returned device mark the appropriate symbols Company data I hereby certify that the returned equipment has been cleaned and decontaminated according to standard industrial practices and is in compliance with all regulations This equipment poses no health or safety risks due to contamination Type of device sensor Serial no Medium concentration Temper...

Page 66: ...Declaration of Contamination Form Average Temperature Water Bottom Sensor and Converter 56 Installation and Operations Manual ...

Page 67: ...n 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 ...

Page 68: ...Index Average Temperature Water Bottom Sensor and Converter 58 Installation and Operations Manual ...

Page 69: ...Varec Inc 59 4532 NOTES ...

Page 70: ...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 www varec com Your official representative ...