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Tank Gauging System

1. Figure 4 14 RS 232 ports TRL 2Bus When one of the RS 232C Interface ports is used a special poares FOM jumper must be connected Terminal X10 jumper in X5 Terminal X11 jumper in X6 On X10 or X11 the terminals 1 4 and 6 have to be connected as well as terminals 7 and 8 See the instruction inside the box beside the terminal Jumpers for RS 232C Figure 4 15 Connect a jumper to the X5 or X6 terminal when a RS 232 terminal is used 4 43 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 2 3 Power Supply 4 44 4 2 4 Power supply can be selected as either 115 V or 230 V with a switch See Figure 4 16 If the switch is set to 115 V the box on the label of the FCU must be marked NOTE Do not turn the switch all the way around as it may damage the switch Figure 4 16 Selection of voltage for power supply on FCU Fuses There are two 100 mA fuses inside the FCU box See Figure 4 17 Figure 4 17 Location of the two 100 mA fuses inside the FCU box Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 2 5 Write protection and Reset There is a write protection switch in the FCU which is used to prev
2. 1 The Field Communication Unit FCU acting as a master on the TRL 2 Field Bus sends a query for level data to the RTG 2 The RTG and its associated DAU PU detect the query for level data 3 The RTG acting as a slave replies with the current level value 4 The associated DAU picks up the level value that is sent by the associated RTG to the FCU Figure 3 21 DAU level pick up A prerequisite for the DAU to correctly pick up level data from the associated RTG is that the address of the RTG is known by the DAU Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 3 Device Description 3 3 10 Automatic test of temperature references The reference resistors are automatically tested by calculating the ratio between the temperature references Al ef LO of This value is put into Input register 10 The ratio is compared with a nominal value which depends on the selected temperature range The tolerance of the value is set in Database registers 307 310 3 4 Remote Display Unit 40 RDU 40 The RDU 40 is a display unit for use with Rosemount TankRadar Rex and Rosemount TankRadar Pro The display functions are controlled by the software of the connected TankRadar gauge Figure 3 22 RDU 40 can be configured to show various measurement variables such as Level Temperature Volume etc For installation instructions see section RDU 40 on page 4 69 The R
3. E ns 5 0 0 0 0 0 50 40 30 10 20 25 30 40 50 60 70 Pt10 Cu90 Resistance Elements Figure 4 27 Pt 100 and Cu90 temperature 4 56 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 3 3 The X21 terminal Connect temperature sensors Chapter 4 Service Exchanging the External Reference Resistor The external reference resistor must be changed if a different temperature measurement range will be used see 4 3 1 Also if the local display shows a reference resistor calibration error it may be necessary to replace it The reference resistor is connected to channel 15 of the multiplexer The reference resistance values corresponding to different temperature ranges and sensors are given in the table below 50 125 50 300 200 150 Figure 4 28 illustrates how to connect the external reference resistor to the X21 terminal DAU Connect Reference Resistor to terminals 43 44 and 45 Figure 4 28 Connection of reference resistor Automatic test of reference resistors The internal reference resistor is placed on the Motherboard The ratio between the high and low temperature references is calculated as a test of the reference resistors This value is compared with a value given for the current temperature range The ratio is allowed to deviate a certain amount from the nominal value The tolera
4. Hazardous areas are classified according to the probability that an explosive atmosphere is present and this dictates whether or not a particular explosion protection technique may be used 2 1 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 2 Safety August 2010 IMPORTANT For trouble shooting and repair work of components in or in connection to intrinsically safe equipment strict observance of the following rules is necessary e Disconnect the power supply to the Radar Tank Gauges and Field Communi cation Units Use a certified battery operated instru ment only Use Rosemount original spare parts only Replacement with non original spare parts may jeopardize the intrinsic safety 2 2 Explosion Proof Explosion proof enclosures can be used when an explosion can be allowed as long as it does not spread outside the enclosure The enclosure must be strong enough to withstand the pressure and must have narrow gaps to allow the pressure to escape without igniting the atmosphere outside the equipment IMPORTANT Any substitution to non recognized parts may impair intrinsic safety The explosion proof flame proof enclosures of the Radar Tank Gauge and the Data Acquisition Unit must not be opened while the units are powered 2 2 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 3 Device Description 3 Device Description 3 1 RexRTG 3 1 1
5. AE Network Connections E m This Workstations H E Devices e e FCLI 1 Uninstall View Input Registers Save Database to File View Holding Registers View Input Registers View Holding Registers Program Calibrate Manual Control Relay 1 Manual Control Relay 2 Hart Devices Status User Defined Linearization Table User Defined Formula LPG Setup Hybrid Setup Enraf Emulation Properties 1c For further information on viewing and editing database registers see TankMaster WinSetup Reference Manual See also the Rex Input Holding Register Descriptions Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 1 3 Chapter 4 Service Loading and Saving a device database Each device RTG DAU and FCU is equipped with a database of parameters used by the Application Software to control the performance of the device TankMaster WinSetup offers the option to load a new database to replace the current one This can be useful if for example you want to try out new database settings and then want to reload the original database The Save Database to File function in the TankMaster WinSetup is used to store the registers from FCUs RTGs and DAUs The main use of the Save Database to file function is for service purposes The registers can be stored into files on the hard disk of the PC or to a diskette To load save database registers Select the d
6. Note that all measured values are adjusted according to the calculated Calibration Distance In the Calibration Data window you can also see that the level values measured by the transmitter are adjusted Of course the hand dipped levels are unaltered Ww Calibration Data Ea Hand Dipped Level mm S446 Level mm Delta Enable Date Time Operator Jal a 3828 1 amp 8111 1 11977 1 16103 T OO O O K K K El MOTE The tank should be measured at minimum 4 different intervals 20 40 60 and 80 of the tank height Save calibration data in PC database Refresh Cancel Help Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 5 Calibration August 2010 5 8 Service Manual 308012En Ed 1 Rev D August 2010 6 Troubleshooting SYMPTOM No contact with RTG No contact with DAU Not possible to write to DAU or FCU CAUSE Faulty TRL 2 bus connection Incorrect address or Unit ID Analyze communication Field Bus connected to wrong communication port on the PC Incorrect or faulty cable connec tion between PC and FBM Unit connected to wrong field bus port of the FCU if an FCU is included Group Bus connected to wrong communication port on the PC if an FCU is included Faulty FCM card if an FCU is included Faulty Field Bus Modem FBM Same as above No contact with associated RTG Incorrect configuration of RTG Incorrect power supply fro
7. 20 800 mA Low Current 3 800 mA Value 104 572 mm Current 8 304 m Status OK Value Units Filter Factor mm a 4 000 Description WBS iM Enable OK Cancel i Set the following parameters HART slaves up to three HART slaves can be connected to Analog 1 using address 1 3 see the TankRadar REX Installation Manual In this case the current is set to 4 mA In Analog Current mode only one HART slave is allowed In this case address 0 must be used Value range enter the lower and upper limits corresponding to the 4 mA and 20 mA input currents respectively Error limits defines the lower and upper limits of the input current Outside this range an error will be indicated Set the lower error limit to 3 4 mA and the upper error limit to 20 24 mA corresponding to the error limits of connected instruments If for an example an instrument sets the output current in alarm mode to 3 8 mA you should set the lower error limit to 3 8 or higher Value unit choose a suitable measurement unit You can choose between various units to indicate pressure product level and current Filter factor set a value between 1 and 200 to suppress spurious fluctuations in the analog input signal Default value is 4 For information on Analog Input configuration see also the WinSetup Reference Manual Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Status information
8. 5 256 in RTG 3900L 3 mm 1 8 in Max 230 C 445 F 40 C to 70 C 40 F to 158 F 0 8 to 20 m 2 6 to 65 ft below flange Can be extended to 0 3 to 30 m 1 to 100 ft below flange with reduced accuracy 0 2 to 2 bar 2 9 to 29 psig Antenna Acid proof steel type EN 1 4436 AISI 316 Sealing PTFE O ring FPM Viton Approximately 20 kg 44 Ibs excl flange 8 in ANSI B 16 5 150 Ibs DN 200 PN 10 DIN 2632 552032 Service Manual 308012En Ed 1 Rev D August 2010 9 3 RTG 3930 Instrument accuracy Operating temperature in tank Ambient temperature Measuring range Pressure Material exposed to tank atmosphere Total weight Manway size Rosemount Tank Radar Rex Chapter 9 Technical Data RTG 3900 0 5mm 5 256 in RTG 3900 L 3 mm 1 8 in Max 230 C 445 F 40 C to 70 C 40 F to 158 F 0 8 to 40 m 2 6 to 130 ft below flange Clamped 0 2 to 0 2 bar 2 9 to 2 9 psig Welded 0 2 to 10 bar 2 9 to 145 psig Antenna Acid proof steel type EN 1 4436 AISI 316 Sealing PTFE O ring FPM Viton Appr 25 kg 55 lbs excluding flange Minimum 20 in 9 3 Rosemount Tank Radar Rex Chapter 9 Technical Data 9 4 9 4 RTG 3950 Instrument accuracy Operating temperature in tank Measuring range Pressure two versions available Material exposed to tank atmosphere Total weight Still pipe dimensions Ser
9. Relay states Alarm In this state the relay is deenergized Normal In this state the relay is energized Toggle The relay switches periodically between Normal and Alarm Select source Specifies the transmitter variable that triggers the switching of the relay Switch Delay This is the time delay until the relay switches into alarm state e the amount of time it takes for a relay to respond to an alarm You can use this to prevent the relay from being activated due to temporary variations of the source signal Toggle Period When the relay is in Toggle state it switches between On and Off at a rate defined by the Toggle Period Control Mode Manual The relay can be manually controlled by choosing the Manual Control Relay option from the Service Devices menu Auto The relay state is controlled by the transmitter variable specified in the Select Source field Disabled The relay function is turned off Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 v 2 gt 2 O E gt Chapter 4 Service Relay Functions You can use one or two set points for relays connected to the Rex transmitter Consequently there are two or three zones in which different relay states can be specified For each zone you can set any of the three available relay states Normal Alarm or Toggle For each set point you can specify a hysteresis zone which will prevent the relay from switching back to its
10. If it is not OK this is indicated in status registers and a default database is restored in the EEPROM and RAM The program will also conduct memory tests during the usual chores The RAM test is run approximately every 20 th second The EPROM and EEPROM tests are run at intervals of 80 minutes separated by 40 minutes It takes two consecutive errors to be detected before the error is signaled to the bus master Local Display The DAU is equipped with an LCD display as a Local Readout function The display shows the level of the associated RTG values measured by the DAU itself and error codes TankRadar L 2 Data Acquisition Unit Type DAU 2130 Figure 3 20 DAU LCD display 3 27 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 3 9 Level value pick up Note 3 28 There are several DAU functions which require level data from the associated RTG e The optional DAU local display can show tank level measured by the associated RTG In order to calculate a correct product temperature it is necessary to exclude the temperature sensors above the product surface from the calculations The DAU constantly listens to the communication that takes place on the TRL 2 Field Bus The DAU is able to detect a query for level data to its associated RTG The following process takes place when a master sends a query for a level value to an RTG connected to the TRL 2 bus
11. foio Auto Hysteresis in absolute value First Point Paint Hysteresis Use both points 1 0000 0 1000 Use one point aene d SECOND 18 0000 Source POINT Relay State in Zone 3 14 30001 Select Source Alarm Resell arm Aese Level m Zone 2 Relay State in one 2 Switch Delay Toggle Period Noma El ita OO os fo fo ae FIRST 1 0 gs 45 0 l POINT 1 0000 Relay State in Zone 1 Disable Invalid Variable Alarm Toggle Alarm Normal Zone 1 Relay Status Actual Source Value 14 46754 OF Description Normal Active Alarm Hot Active o pened Closed DE Cancel Help 4 Set the following parameters Using first both points To define three relay zones select Use Both Points To define only two relay zones select Use Only First Point First and second set points The first and second set points define the transitions between Zone 1 2 and 3 You can set different relay states in each of these zones Hysteresis When the source variable passes a set point the relay switches from one state to the other If a hysteresis zone is specified the relay remains in the new state even if the source signal returns back to a value within the previous zone How far it will remain in the new state is defined by the value given in the hysteresis input field 4 37 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 38
12. 2010 Chapter 3 Device Description 3 1 7 Inputs and Outputs Inputs The gauge has up to 6 temperature inputs directly into the gauge up to 14 temperature inputs to each gauge via separate Data Acquisition Unit e two 18 bits high accuracy analog inputs for e g pressure transmit ters or water bottom sensors The gauge can act as a single HART master using one analog input to interface intrinsically safe digital HART inputs from up to 3 HART based sensors Technical Data Analog inputs Accuracy 20 uA Input range 4 20 mA Update range 0 5 Hz Low alarm level lt 3 8 mA configurable High alarm level gt 20 7 mA configurable Umax from TIC 25 2 V Imax from TIC 96 mA P max from TIC 0 6 W Available voltage 13 7 V at 20 mA Outputs The gauge has e two relay outputs non intrinsically safe to be used for level tem perature or other alarms 250 VAC 4 A The relays are approved for overfill safety by T V and have function feedback Operation is selectable as normally open or normally closed one optional non intrinsically safe Analog output The Analog out put replaces the second Relay output Technical Data Relay outputs Contact rating resis 250 V 4A tive load Contact life 100 000 op 3 11 Rosemount Tank Radar Rex Chapter 3 Device Description 3 12 Service Manual 308012En Ed 1 Rev D August 2010 Technical Data Analog output Type Galvanic isolation Range Alarm
13. 4 49 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Hardware installation e Connect the special three wire cable between the RS 232 ports of the FCUs The cable shall be connected to the RS 232 port 2 con tact Figure 4 23 Connecting the RS 232 ports e If a TRL 2 bus is connected to GB2 use an FCM board with spe cial jumper Note The old version of the standard FCM board can not be used at port 1 when redundant FCUSs are used e If an RS 232 bus is connected to GB2 use separate communica tion lines from the workstation to the primary and backup FCU respectively COM 1 x COM 2 RS 232 ECU mna cere BS Ses Redundancy cable Field Bus 1 Field Bus 2 Figure 4 24 Using an RS 232 Group Bus connection 4 50 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Note 10 11 Chapter 4 Service Software configuration For further information on how to configure install the FCU see TankMaster WinSetup Reference Manual Power down both FCUs Power up one of the FCUs Select the Devices folder in the TankMaster WinSetup workspace win dow click the right mouse button and choose the Install New option Choose device type FCU specify a name in the Tag input field and click the Next button to continue Select a communication channel Set the FCU address 1
14. 66 Multiple Echo Tracking 0 0 0 ccc eee ee 3 6 P Parabolic Antenna Gauge nannaa aa ee es 3 1 3 2 POWer OUDDIV ecserin irian desidia ee 4 44 4 67 lo ll El tre ttc ees A O adh aoe atta er ae 4 31 Properties Tank Distances 0 0 cee ee eee eee 5 5 R DA rre Bhogal Mas aie sae aa ae aia an O 1 3 PCGUMGANCY sanos Peers eee SSeS Re ee FER Se ee as eae Seu 3 20 4 49 Reference resistor veria a wee Louvered eee wee del 3 24 4 54 AULOMAUGICSE assi gary O a a cba eS 4 57 EXCHANGING 00d A AAA e eee 4 57 Relay FUNCIONS cs decorada ti 4 39 Relay QUIDUL escotorarrasriaa tadas stands 4 35 Relay OULDUl CaN suecas eee de oe fe e e AA EA GE ee ee het 3 8 Relay Slales dica Goa a el ii ide a ees 4 38 Remote Display Unit 40 6 s44c306024 60640084 4550450 0 44454000045 G084 3 29 PRE MIOVING ne ERE eine ies aca ne ean db eae a Ue dy Gok aid eee 4 10 BRO DIAC TIC UNS TAHE anat de Doane eee Ga eternal SS EN oh aed le e 4 11 RTOMUNDPIEX ceci ants biG tie ned eed oe sO A sd dio ba 3 25 RTG Communication timeout 0 0 0 0 ee 4 66 S Sa Wi a io DS ee A a a Sake Pee otek 2 1 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Index August 2010 SCICCI SOUICE was ga aia bed hee See ONES oes a eee we eRe he 4 38 Service DAU 2d tara 4 54 A ta ate Set Se sects east tates the ged te a de aA ep ede ses dog a tase ease ee 4 67 POU a io A ia Sa oe waa Se 4 41 OS saat tas tact A te WG 4 69 SEPON correas Bla ora he
15. Address ho Unit ID Ea Wersiory Accociated DAU Software version Check that the Software version on the label of the EEPROM correspond to the version displayed in TankMaster 4 9 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 1 6 Exchanging the Transmitter Head Electronics Note Make sure that power is turned off Removing the THE 1 Check if there is any screw that is sealed Contact Rosemount Tank Gauging before breaking the seal if warranty is still valid Completely remove the seal so that it does not damage the threads Loosen the screws and remove the cover 2 Loosen the two screws which hold the electronic unit 3 Carefully lift the Electronic Unit Remove the cable connectors Han dle the Electronic Unit carefully Be especially careful with the PTFE plug at the center of the bottom of the Electronic Unit Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Replacing the THE 1 Connect the cables to the THE See Figure 4 1 below Press firmly so that the connectors lock into place Connection to the TIC and TMC board for further infor mation see TIC TMC Con figuration on page 4 16 Connections to the ROC board for further information see 4 1 12 Mother Board MB Connection to the MB The 6 pin connector cable shall be connected to the X20 on the MB The Analog Output
16. EE Paws 3 1 Transmitter Head Electronics e eee 3 1 3 7 Transmitter Interface Card o o o oooooooooooorrrn eee 3 8 Transmitter software o o o o o o o o ee ee es 3 17 IOUDIESHOOUNG vs sarro a ee hd Sa aa ia Sen ee 6 1 U USING IESUDO PORTS tera o e Boer es Se bb ees oes 4 37 V Viewing and Editing database registers 0 0 eee ee 4 2 W W SUD Pts dh estas aes tas Gee de indio daa eG eae hee eh ee 5 1 WinSetup Calibrate function 0 0 es 5 3 Write protecting the EEPROM 0 0 ccc es 4 13 Write protection aii wats Ate oe eee a Se ees 3 9 4 13 Write protection and Reset 0 0 ccc ee eee 4 45 Write protection Switch 0 0 0 0 0 ee ee ees 4 59 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Index August 2010 Service Manual 308012En Ed 1 Rev D August 2010 Rosemount Tank Gauging local representative Emerson Process Management Rosemount Tank Gauging Box 130 45 SE 402 51 Goteborg SWEDEN Tel International 46 31 337 00 00 4 Fax International 46 31 25 30 22 E mail sales srt emersonprocess com www rosemount tg com E M E RSO N l E A a a A A Process Management Ref no 308012En Ed 1 Rev D August 2010 2
17. H7 H9 H11 received Yellow LED Serial Data H10 transmitted CNN i Red LED Watchdog time H13 out CPU reset Green LED Power on H14 4 46 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service The location of the Field bus and Group bus connections are shown in Figure 4 20 Figure 4 20 The location of Field and Group bus connections on the FCP board The microprocessor of the FCU is the 80C188 It contains a DMA controller Direct Memory Access which allows the processor to process other information while the DMA controls data between the RAM memory and the serial ports There is RAM Random Access Memory of 32 KB for the data buffer The data buffer is used to store the information from the slave units The EPROM is used to store the program When exchanging the EPROM it is strongly recommended that the FCP board is removed from the FCU box for better access of the memory chip The EEPROM is used to store database registers and can be remotely reprogrammed if the write protection switch is in the write enable position There are three dual channel Serial Communication Controllers SCC that control the six serial communication ports for Group Bus and Field Bus communication 4 47 Rosemount Tank Radar Rex Chapter 4 Service 4 48 Crystal 16 MHz Power mon gt 4 5 Watch dog 10s Power supply Filter Switch Serial Communications Controller Processor S
18. If the input values are incorrect or are not shown in TankMaster check the following e Analog Input Configuration see Software configuration Analog inputs on page 4 22 Device Error and Device Warning status in Input register 2 e Analog Input Status connection status calibration mode above under limit etc and the Analog Input Value in Input registers 4420 4434 Analog Input Value Unit Filter Factor Lower Upper range High Low current limit Calibration method etc in Holding registers 3200 3270 e FCU configuration check the number of Analog Inputs in the FCU Slave Database 4 23 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Note 4 24 4 1 10 Analog outputs The Multi Field Communication Card version 9150072 673 or later is required Rex supports one analog output signal The analog output replaces the second relay output In this case the Relay 2 cabling is disconnected from the Relay Output Card ROC and connected to the MotherBoard The FCC board must be configured for Analog Output Jumper settings are required depending on if the Current Loop Output is active internal loop supply or passive external loop supply Field Communication Card FCC Figure 4 8 Field Communication Card FCC Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service FCC Configuration of Analog Output In
19. System Description August 2010 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 2 Safety 2 Safety TankRadar Rex equipment is often used in areas where flammable materials are handled and where an explosive atmosphere may be present To protect both the plant and the staff precautions must be taken to ensure that this atmosphere cannot be ignited These areas are called hazardous areas and equipment within these areas are explosion protected A number of different explosion protection techniques have been developed over the years Intrinsic safety and explosion proof or flame proof safety are two techniques 2 1 Intrinsic safety Intrinsic safety IS is based on the principle of restricting electrical energy available in hazardous area circuits such that any sparks or hot surfaces that may occur as a result of up to two electrical faults in components are too weak to cause ignition Intrinsic safety is the only technique accepted for Zone O high risk hazardous areas It is also safe for personnel and allows equipment to be maintained without the need for a gas free certificate The basic principles of intrinsic safety are All flammable materials are grouped according to the energy needed to ignite them Equipment located in hazardous areas are classified according to the maximum surface temperature that it can produce and this must be safe with the flammable gases that may be present
20. and Multiple Spot sensors Avg CU90 for Average Temperature sensors User Defined The characteristics are specified by a mathemati cal formula or a linearization table see WinSetup menu option Service gt Devices gt User Defined Linearization Table Formula Troubleshooting If the temperature values are incorrect or are not shown check the following TankMaster WinSetup click the right mouse button on the Rex icon and choose Properties gt Configuration gt Temp Input Check that the Enable Disable check box is selected Check the sensor position The Device Error and Device Warning status in Input Register 2 The Temperature sensor status in Input Register 27 e The Temperature sensor status in Input Registers 4460 4466 4472 etc Double click the Status field for detailed information The temperature values in Input Registers 4462 4468 4474 etc The Sensor resistance values in Input Registers 4464 4470 4476 etc e Jumper settings and cable connections see TIC TMC Configura tion on page 4 16 e FCU Slave Database configuration see WinSetup Reference Manual check that the right number of temperature sensors are given Also check that Interval 2 is set to 10 See chapter 4 3 2 for information on how to check the temperature sensors For a general overview of status and configuration check Holding Registers 3300 3542 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex Augus
21. changed by either replacing an EEPROM or by downloading through the TRL 2 bus Both programs must be changed simultaneously The EEPROM contains both the Boot and the Application programs The transmitter software performs actions as Internal initialization Communication handling Implementing measurement features Internal checks For further information see Chapter 4 1 5 3 17 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 2 Field Communication Unit FCU Note The Field Communication Unit FCU acts as a master of communications on the Field Bus and as a slave on the Group Bus The FCU is an intelligent data concentrator that continuously collects input data from a group of Radar Tank Gauges and Data Acquisition Units and stores it in a buffer memory The heart of the FCU is a microprocessor with RAM and EEPROM for data and program storage The FCU is delivered in an IP 65 weather protected wall mounted box of the same type as for the Data Acquisition Unit See Figure 3 13 TankRadar L 2 Type FCU 2160 Ground Connection Cable Outputs Figure 3 13 Field Communication Unit FCU 2160 No explosion protection is provided so the Field Communication Unit must be installed in a non hazardous area Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 3 2 1 Chapter 3 Device Description Field Bus and Group Bus
22. es ae pea a a cette cies ant Ghd e Byes 4 1 How to initiate an echo search o o o o ooooooo 4 1 Viewing and Editing database registers 4 2 Loading and Saving a device database 4 3 Loading the default database 4 4 Installing new Transmitter Software 4 5 Exchanging the Transmitter Head Electronics 4 10 Write protection Metrological Seal 4 13 Temperature measurement o o o oooooooooooo o 4 15 ANAG INDUS 22 AA ee Ca ee Boe eS 4 21 Analog outputs ici yale tie Schepers aOR Goede hel ak ae e 4 24 HART WOU a oe are Weg ie uae aoe as 4 33 Relay OUIDUC xxi a Wee s aK 4 35 shee Fie Os EOIN eels a ia Wet anh tact a 4 41 Default database loading lt o 4 41 Group and Field Bus PortS o o o ooooo o 4 43 POWG SUDDIV sigri crena e a IS A 4 44 FUSOS zadig nane a E E NA A iia 4 44 Write protection and Reset 0 ccc eens 4 45 EICCUONICS Ariinae astern a eS apa a ae a ea 4 46 Redundancy option lt o o 4 49 A Lees e a bere ota ee oe 4 54 Setting the temperature measurement range 4 54 Checking the Resistance Temperature Detectors 4 56 Exchanging the External Reference Resistor 4 5 Suppressing error indication o 4 58 DAU TOS CL rivas g aed dia aio ia Ge 4 58 Write Protection oe sig cist a il a ad Be aie Gt Seda 4 59 Default da
23. level Resolution Linearity Temperature drift Output impedance Voltage compliance External loop resis tance Analog 4 20 mA current loop passive or active output external or internal loop supply gt 1500 V RMS or DC 4 20 mA 3 8 mA 22 mA freeze current Binary High or Binary Low software select able 0 5 mA 0 003 0 01 50 ppm C gt 10 MW 7 30 V lt 700 W passive output with 24 V external supply lt 300 W active output Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 3 1 8 Chapter 3 Device Description Database Registers Holding Register The Holding registers store various transmitter parameters used to control the measurement performance The database is stored in the non volatile EEPROM memory It contains tank constants and data controlling the RTG performance These data is used by the Application Software in order to calculate product level and other values of interest Since the RTG measures the distance from the RTG to the product surface the dimensions of the tank are needed in order to calculate the actual product level The information needed to transform the measured distance into level values is stored in the database registers C A Ullage RTG Y W TankMaster Figure 3 11 Using information from the database the measured ullage is converted to tank level The database contains other values than tank dimens
24. microwave signal with a continuously varying frequency towards the liquid surface When the reflected signal returns to the antenna it is mixed with the outgoing signal Frequency f GHz Figure 3 5 The FMCW method The distance d is calculated my mea suring the frequency distance Df between the transmitted frequency f1 and the reflected frequency f0 Since the transmitter continuously changes the frequency of the transmitted signal there will be a difference in frequency between the transmitted and the reflected signals The gauge mixes the two signals resulting in a low frequency signal which is proportional to the distance to the liquid surface This signal can be measured very accurately allowing fast reliable and accurate level measurements Rex uses an optimum microwave frequency which reduces sensitivity to vapor foam and contamination of the antenna and keeps the radar beam narrow in order to minimize influence from walls and disturbing objects Fast Fourier Transformation FFT Rex uses FFT which is a well established signal processing technique to obtain a frequency spectrum of all echoes in the tank From this frequency spectrum the surface level is extracted In combination with Rosemount s Echofixer FFT allows measurements in tanks with agitators mixers and other disturbing objects Echofixer Rosemount s Echofixer provides a technique to adapt measurements to various situations by using info
25. nana pad ias 5 5 Calibration Distance ooooooocoronao ner 5 1 5 7 Calibration WINdOW 2 ruca ad ira es Seedy eee here 5 6 Cnanging EEPROM cocos suas teens ae doe tooo eee eget ieee eee ae pen 4 7 Connecting the relay ports 0 0 0 0 0 cc ees 4 35 CONNeCHONNO APC 264d asa inier A Feed tae Sees eee es 3 21 Gontrol MOde 5 acct dace aeredans rar i wees 4 38 Correction values OI pra a Sf ae ee es a E Aa ee 3 14 D Database loader ciar Ai OES 4 60 Database Registers Holding Register ctas ie beheaded oon A 3 13 MSU HR COI SUC Ree Stace Sie aaa een tate O Ble a Ieee etter A oth dee ae eee 3 14 DAW LCD DISplay errar d cht dea SS wkd Gs Rane Oe eee ee aR aS 4 61 DAUHCVEL DICK UD i iria ista cathe oes coed eade teed ede ee 3 28 PAURE SOU arca acai tous an Saar ads entre eee ees hee aaa alr ee ae 4 58 A SONWANE uetouical San aed a tet e haat a aye a ae ee o 3 26 Default Database serra ia BE dS Be Se ERA SH 4 4 Default database loading nana cc eee 4 41 Default database reload 1 0 0 ee ees 4 60 Device descrploM hice Gash ew bee atoaeer eas aes a 3 1 Data ACGUSITION Ulla a eae oN ee Saw BE Sed ea BARS oS 3 22 Field Communication Unit 0 0 0 ccc ee 3 18 A Se eens tate Scat Ses 09 cde he tyson 10 oe Gy geoph A 3 1 Display MdG O as ccs ot cut on Gee ad 4 62 DISDIAY MOJE Ds e E oe es Sct be ahi eis Se Gor ee oe owe 4 63 DISDIAY MOOG A pia a acon bk Se oe ee ee i ee did 4 64 E ECMO SC A Mai
26. oo 3 10 3 1 7 Inputs and OutputS 0 00 000 ee 3 11 3 1 8 Database Registers o ooooooooooooooooo o 3 13 3 1 9 Tank Geometry o ooooooocononn ete 3 16 3 1 10 Software Description 0 00 cc ee 3 17 3 2 FIELD COMMUNICATION UNIT FCU 3 18 3 2 1 Field Bus and Group Bus Communication 3 19 3 2 2 Input and Database Registers 3 19 3 2 3 SON WAC e iea ea traider Sea deat 3 20 3 2 4 FROOCUNOANCY se sE es Banks dws 3 20 3 2 5 GONASCUON IO APG Ss Shek eee 3 21 3 9 DATA ACQUISITION UNIT DAU 005 3 22 O94 OVEIVISWO sti a a a 3 22 3 3 2 Data Acquisition Unit DAU o o o o 3 22 3 3 3 BICORNIS pits A AAA AAA 3 23 3 3 4 Temperature Measurement o ooooooooooo 3 24 09 9 RTD Multiplexer o o oooooocoonoroomoc 3 25 3 3 6 DAU SOHWAIC vice 2 Re EPIL Be BER SRE Ree Bek 3 26 337 Database Registers 0 00 cee 3 27 3 3 8 LOCA DISDIQYV wx sa4 bho A SA AI e 3 27 3 3 9 Level value PICK UP 0 ee ee 3 28 3 3 10 Automatic test of temperature references 3 29 3 4 REMOTE DISPLAY UNIT 40 RDU 40 3 29 TOC 1 Rosemount TankRadar Rex Contents 4 TOC 2 SERVICE 4 1 4 2 4 3 4 4 4 5 REX RTG 4 1 1 4 1 2 4 1 3 4 1 4 4 1 5 4 1 6 4 1 7 Service Manual 308012En Ed 1 Rev C August 2010 EE EE AEEA EEEE EEEN 4 1 Sent Ge de aa Bh dies Seve
27. the FCC board with the metrological seal 4 13 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 3 Remove the plastic cover and turn the switch to the right m o Write Enable Protect 4 Replace the plastic cover and seal the switch in the write protect posi tion 5 Replace the FCC board and the PCB locking Check that contact surfaces on the trans mitter housing and cover are clean Replace the cover and tighten the screws Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 1 8 Chapter 4 Service Temperature measurement The Rex transmitter can be connected to 1 3 single spot temperature elements or to 1 6 multiple spot common return or average elements if the Temperature Multiplexer Card TMC is installed Max 6 sensors can be connected to the transmitter sensor number 1 must have the lowest tank position etc The sensors must be of the same type average or spot The TMC board must be configured in accordance with the type of sensor that is used see Transmitter Interface Card TIC Temperature Multiplexing Card TMC Figure 4 2 Transmitter Interface Card TIC and Temperature Multi plexing Card TMC 4 15 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Note 4 16 TIC TMC Configuration The TMC board is configu
28. to take the cable into the RDU40 2xM20 Cable diameter 7 mm 14 mm 1xM25 Cable diameter 9 mm 18 mm External adapters 1 2 NPT and 3 4 NPT are optional Connect the RDU 40 to the X12 terminal in the Rex junction box as illustrated in Figure 4 35 4 69 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Note 4 70 In order to allow proper operation and to fulfil EMC requirements the cable between the RDU 40 and the Rex junction box should meet the following requirements Shielded cable Minimum 3 wires The shield shall be circular con nected inside the cable gland of the RDU 40 and connected to ground in the Rex junction box All wires must have at least 0 25 mm individual insulation e Maximum total length of 100 m both master and slave included Minimum AWG 20 or 0 5 mm for each wire The RDU 40 chassis shall be grounded locally to the tank Use minimum 4 mm or AWG 11 wire Additional protective ground connection to the power distribution central or the Rex junction box is not recommended except where required according to national code of practice A ground loop with circulating current may occur It is not possible to use an RDU40 and a DAU simultaneously Figure 4 36 Back of RDUA40 If a cable with two shields is used one shield shall be connected to ground in the Rex junction box and the other shall be circular connected inside the cable g
29. 931 9240 003 933 9240 007 987 9240 007 988 9240 007 989 9244 000 904 9240 002 909 9240 002 910 9240 003 912 9240 003 940 9240 003 941 Service Manual 308012En Ed 1 Rev D August 2010 9 Technical Data 9 1 RIG 3900 Rosemount Tank Radar Rex Chapter 9 Technical Data The following specification is valid for RTG 3900 standard version Ambient operating temperature Hazardous locations certifications Instrument accuracy Power Supply Field Bus 40 C to 70 C 40 F to 158 F Il 1 2 G EEx dlia IIB T6 Tamb 40 C to 70 C according to ATEX directive EN 50014 EN 50018 EN 50020 EN 50284 Europe and Class 1 Div I Groups C and D according to UL 1203 UL 913 UL 508 USA IECEX d IIB T6 Tamp 40 C to 60 C RTG 3900 0 5mm 5 256 in RTG 3900 L 3 mm 1 8 in 100 240 VAC 50 60 Hz average 15 W max 80 W at gauge power up in temper atures below freezing point 34 70 VAC option 20 28 VDC max 30 W option 48 99 VDC option 1 TRL 2 Bus FSK half duplex two wires galvanically isolated 4800 Baud Modbus based 2 RS485 Modbus based 9 1 Rosemount Tank Radar Rex Chapter 9 Technical Data 9 2 9 2 RTG 3920 Instrument accuracy Operating temperature in tank Ambient temperature Measuring range Pressure Material exposed to tank atmosphere Total weight Mounting flange Service Manual 308012En Ed 1 Rev D August 2010 RTG 3900 0 5mm
30. AU Exchange PCB DMB for Slave DAU or DXB for Independent DAU See the items above No action required Restart the DAU See items under No contact with RTG or DAU Restart the DAU See items under No contact with RTG or DAU See the items above 6 5 Rosemount Tank Radar Rex Chapter 6 Troubleshooting DAU Display CAUSE Internal serial communication FTE 2 setetes oro Internal serial communication FU ditt se 1 Error detected Internal serial communication FFT Peena vus tenre Temperature measuring error EUuudd 0 No detected error Temperature measuring error AHHH i 1 Error in at least one sensor Temperature measuring error PHOT AL 2 Calibration error Reference signals out of range Temperature measuring error SHE 3 Average error Not any functioning non blocked sensor is within the product Current input error p for pres FOOTE e A O No detected error Current input error p for pres EQUBO L Ekorn atieastone sensor 6 6 Service Manual 308012En Ed 1 Rev D August 2010 ACTION No action required Restart the DAU Exchange PCB DMB for Slave DAU or DXB for Independent DAU Restart the DAU Exchange PCB DMB for Slave DAU or DXB for Independent DAU No action required Watch display in
31. Alarm mode Low Current Alarm mode High Current Alarm mode Freeze Current Alarm mode Binary High Alarm mode Binary Low Analog Output current as a function of product level for different alarm mode settings The shaded area indicates analog output in alarm mode Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 32 Following alarm modes are supported in Rex Table 4 1 Alarm Modes Alarm Mode Current Output High Alarm 22 2 MA Freeze The current that was output the last valid measurement Binary High 4 mA for valid measurements 20 mA output when in Alarm Mode Binary Low 20 mA for valid measurements 4 mA output when in Alarm Mode The Analog Output goes into alarm when The measurement value goes outside the approved range Measurements are invalid An error is detected in the gauge For an overview on the Analog output signal status see Holding Register 2000 2146 See also WinSetup Reference Manual for further information on how to configure the analog output Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 1 11 HART Input Hart Slaves are connected to Analog input 1 Connection to HART devices requires a Multi Field Communication Card equipped with optional HART modem X12 Oo 01 amp NM 09 Figure 4 10 Connection of HAR
32. C Requirements USA only Rosemount TankRadar Rex generates and uses radio frequency energy If it is not installed and used properly that is in strict accordance with the manufacturer s instructions it may violate FCC regulations on radio frequency emission Rosemount TankRadar Rex has been FCC certified under test conditions which assume a metallic tank Installation on a non metallic tank is not certified and is not allowed The FCC certificate for Rosemount TankRadar Rex requires that the tank is closed as far as emitted radio energy is concerned Tanks with open manholes external floating roof tanks without still pipes etc are not covered by the certificate ROSEMOUNT Tank Gauging EMERSON www rosemount tg com Service Manual 308012En Ed 1 Rev C Rosemount TankRadar Rex August 2010 Contents 1 SYSTEM DESCRIPTION 0020 e eee eee ees 1 1 Za SAFETY canoas oad bees 2 1 2 1 INTRINSIC SAFETY uta tat ate Sa mee ele eae 2 1 2 2 EXPEOSION PRODE ts it a ie ed a eae Biba ee eeean ee 2 2 3 DEVICE DESCRIPTION 0e2 lt cess as 3 1 3 1 REX RIG sen dades Soa as eee SSE 3 1 3 1 1 QVEIVICW o SM Sole HES Re BETA A RIES 3 1 3 1 2 Antenna typ S 10 0c ees 3 2 ne Ey Measurement principle o o o o oooooooooo 3 5 3 1 4 Transmitter Head Electronics o o o oooo 3 3 1 5 Write protection Metrological Seal 3 9 3 1 6 Internal calculations o o o oooooooooo
33. CC 1 128 K 8 EEPROM 32 K 8 RAM 32 K g DATA ADDR DMA Controller BUSREQ Figure 4 21 FCU block diagram Service Manual 308012En Ed 1 Rev D Group Bus Interface 1 TRL 2 BUS RS 232 Interface 1 Group Bus Interface 2 TRL 2 BUS RS 232 Interface 2 Field Bus Interface 1 TRL 2 BUS Field Bus Interface 2 TRL 2 BUS Field Bus Interface 3 TRL 2 BUS Field Bus Interface 4 TRL 2 BUS August 2010 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 2 7 Redundancy option Introduction In order to reduce the risk of communication failure between the TankMaster and the units connected to the TRL 2 field bus two FCUs can be connected to run in parallel If one FCU fails the other one automatically takes over without any action from the operator The FCUs are connected with an extra cable allowing them to communicate The inactive FCU constantly checks if the connected FCU is active If the active FCU fails it becomes inactive and signals to the backup FCU to take over Then the backup FCU immediately switches to an active state TankMaster a Field Bus Modem ECU Group Bus FCU FCU Redundancy cable Field Bus 1 Field Bus 2 Figure 4 22 Parallel Field Communication Units connected to the TRL 2 bus
34. Communication The Field Communication Unit has six communication ports X1 to X6 The standard configuration is six TCM interface boards with four TRL 2 Field Bus FB ports and two TRL 2 Group Bus GB ports As an alternative the FCM boards at the Group and Field Bus ports can be replaced with FCI boards for RS 485 communication The FCU communication ports can be configured according to the following table 3 2 2 The Field Communication Unit has six communication ports for the Field bus and Group bus communication The Group Bus ports can be used independently of each other For example one Group Bus can be connected to a PC with OPI software and at the same time another Group Bus may be connected to a plant host computer There are four Field Bus ports each of which can connect up to eight units A unit may consist of a Rex gauge or a Rex gauge connected to a DAU If the number of cables to a Field Communication Unit is higher than the capacity of the connectors then standard Junction Boxes fitted for use in the environment in question can be used to split the connections There is a steel plate to shield the bus ports from the rest of the electronics in the FCU Input and Database Registers The input register is a dynamic register which holds the values that the FCU receives over the TRL 2 bus from connected slave units RTGs DAUs Level temperature and other measured data is stored in the input register and are sent
35. DUAO is used for monitoring measured data To configure a TankRadar Rex gauge use the JankMaster Winsetup configuration software Configuration and installation of the RDU40 is described in the Display Unit RDU 40 User s Guide Ref no 308010EN Note Check that the Rex Software version is 1 D2 or later and that the RDU 40 Software version is 1 B1 or later 3 29 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 30 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 Service 4 1 Rex RTG 4 1 1 How to initiate an echo search There are several ways that an echo search can be initiated e Switch power supply off and on A search is automatically per formed Restart the RTG 1 Select the transmitter icon in the TankMaster WinSetup workspace window 2 Click the right mouse button and choose the Restart option or from the Service menu choose Devices Restart What happens after a power on An internal check of software version and memory status is done The communication is enabled The sweep generation is started A dummy sweep is generated until the sweep is linear warm up mode The level gauging starts with a search through the tank to find the level of the product When the level is found the normal gauging procedure starts What happens during a search A microwave signal is sent towards the product
36. Gauging Receive Transmit Figure 4 33 The Field Bus Modem 4 67 Rosemount Tank Radar Rex Chapter 4 Service 4 4 3 4 68 Service Manual 308012En Ed 1 Rev D August 2010 FBM instead of FCU for small systems In a small system with a maximum of 16 units RTGs or DAUs the Field Bus Modem can be used instead of an FCU The Field Bus Modem can then be connected directly between the TankMaster PC master and the RTGs and the DAUs The Field Bus Modem is contained in a small box and must not be used in a hazardous area TankMaster RS232 Modbus Optional Host Com protocol Optional Second puter or Slave PC Tank Group Control Room Level Field Bus Rex Analog In Analog out Temperature Temp Temp Relay Out HART sensors sensors Figure 4 34 Example of a small TankRadar Rex System Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 5 RDU 40 4 5 1 Installation To access the upper screw of the RDU 40 cover remove the rubber plug Unscrew and remove all six screws Remove the cover and take care of the locking device for the weather protection hatch The RDU 40 shall be connected to the TankRadar Rex junction box for cable connections Jumper Position 1 0 0 O RDU 40 Master Rex Junction Box Figure 4 35 Installation of RDU 40 master and slave Any of the three cable glands may be used
37. INDEX eco tirada rara ee bees A ee INDEX 1 TOC 3 Service Manual Rosemount TankRadar Rex 308012En Ed 1 Rev C Contents August 2010 TOC 4 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 1 System Description 1 System Description The TankRadar Rex System is a monitoring and control system for tank level gauging The system can interface various sensors such as temperature and pressure sensors for complete inventory control There is a distributed intelligence in the various units of the system The units continuously collect and process information When a request for information is received an immediate response is sent with updated information The units communicate with each other on a field bus the TRL 2 Bus No part of the equipment is in actual contact with the product in the tank and the antenna is the only part of the gauge that is exposed to the tank atmosphere The Radar Tank Gauge sends microwaves towards the surface of the product in the tank The level is calculated based on the echo from the surface TankRadar Rex can measure the level of almost any product including bitumen crude oil refined products aggressive chemicals LPG and LNG etc Using a suitable Tank Connection Unit the TankRadar Rex System can gauge any type of tank TankMaster RS232 Modbus Optional Host Com o Optional Second puter or Slave PC Tank Group Control Room Level Field Bus Rex DAU Analo
38. In the FCU Communication window click the Change Address on Device button 2 Enter the Unit ID and the Modbus Address and click the OK but ton 3 In the FCU Communication window click the Verify Communica tion button to make sure that communication is established 4 Click the Next button to continue In the FCU Configuration window choose the Redundant Primary mode option to set the operation mode Click the Next button to open the FCU Slave Database window Config ure the FCU Click the Next button to open the Summary window and then the Finish button to finish the FCU installation Comment The standard mode of operation is normal There is no difference in operation between the FCU designated primary and backup respectively The reason for having different names is only to be able to distinguish between the redundant FCUs Check that holding register 831 7 only memory tests Power down the FCU Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 12 Power up the second FCU 13 Setthe second FCU address It is important that both FCUs are using the same address 1 Select the FCU icon in the WinSetup workspace window click the right mouse button and choose the Properties option 2 Select the Communication tab and click the Change button 3 Enter the Unit ID and the Modbus Address and click the OK but ton 4 Click the Verify Communication button to make sure that com m
39. Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 1 3 spot elements Ze tag int coa l ea A C4 Co S88 8 EE i ai ae O i aot aa a y EE ae 0000000000000 SU 0000000000000000 O Figure 4 5 TMC board configured for 1 3 spot elements e No jumpers in socket X4 and X5 e Connect the 8 pin connector cable to the X3 connector on the TMC board Check that the Temperature sensors are properly connected to X12 see the TankRadar REX Installation Manual ConnectorX12 Figure 4 6 Connector X12 Service Manual 308012En Ed 1 Rev D August 2010 Rosemount Tank Radar Rex Chapter 4 Service 5 Make sure the 10 pin connec tor is connected to socket X2 on the TIC board 6 Carefully attach the TMC on the back of the TIC 7 Replace the TIC TMC board and the PCB locking Check that contact surfaces on the transmitter housing and cover are Clean Replace the cover and tighten the screws 4 19 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 20 Temperature sensor configuration By using TankMaster WinSetup you can configure the transmitter by specifying sensor type sensor range and sensor positions See WinSetup Reference Manual for further information on how to configure the temperature sensors Following options are available in TankMaster WinSetup e Spot DIN PT100 for Spot
40. Manual For a user defined antenna TCL must be manually entered For predefined antennas TCL is automatically set Tank Dimensions Tank Reference The Tank Reference Height R is the distance Height R between the Tank Reference Point and the Zero Level Dipping Datum Point at the bottom of the tank RTG Reference The RTG Reference Distance G is the distance Distance G between the Tank Reference Point and the RTG Reference Point The RTG Reference Point is located at the top surface of the customer s flange or manhole cover on which the gauge is mounted as illustrated in Figure 3 12 For Still Pipe Gauges the RTG Reference point is located at the hand dip mark on the Still Pipe Gauge Stand G is positive if the Tank Reference Point is located above the RTG Ref Point Otherwise G is negative Service Manual 308012En Ed 1 Rev D August 2010 Minimum level distance C Calibration Dis tance Hold Off Distance UFM Rosemount Tank Radar Rex Chapter 3 Device Description The Minimum Level Distance C is defined as the distance between the Zero Level Dipping Datum Point and Minimum Level of the product surface tank bottom By specifying a C distance the mea suring range can be extended to the bottom of the tank If C gt 0 negative level values will be displayed when the product surface is below the Zero Level Select the Show negative level values as zero check box if you want levels below the Zero Level to be
41. Overview The Radar Tank Gauge Rex RTG Rex is an autonomous distance measuring device The distance and level calculations are continuously carried out in the Radar Tank Gauge Upon request from a master the RTG can send the level information status and other information on the Field Bus All Rex gauges consist of two main parts the Transmitter Head TH and a Tank Connection Unit A number of different Tank Connection Units Antennas can be attached in order to satisfy a variety of different applications There are different types of Radar Tank Gauges e The Horn Antenna Gauge RTG 3920 for fixed roof installation without still pipe e The Parabolic Antenna Gauge RTG 3930 for demanding envi ronments without still pipe e The Still Pipe Gauge RTG 3950 for measuring in still pipes e The LPG LNG Gauge RTG 3960 for liquid gas LPG and LNG All antenna types use the same kind of Transmitter Head Electronics 3 1 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 1 2 Antenna types The Horn Antenna Gauge RTG 3920 The Horn Antenna Gauge is designed for an 8 in antenna to be used in small size openings on tanks with fixed roofs The RTG 3920 is designed for measurement of a variety of oil products and chemicals However for bitumen asphalt and similar products the Parabolic antenna is recommended Figure 3 1 RIG 3920 The Pa
42. See Figure 4 30 Write Inhibit Write Enable A A A RR MS A A Figure 4 30 Write protection switch 4 59 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 60 Default database reload Disconnect the DAU power supply Remove the program EEPROM from the socket see Figure 4 31 EEPROM esse lt ces aa a a a a a a a a a a a a e CE E CECE EC CECE E CR EC ECE CEC CEC Figure 4 31 Database loader Insert the DB loader EEPROM into the EEPROM socket Power up and wait for about 30 seconds When the database loading is finished all segments on the local display light up ABBABE Comment flashing display segments indicate that the data base loading failed Disconnect the power supply Remove the DB loader and reinsert the program EEPROM Power up Configure the DAU Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 3 8 Local Display modes The display has three different display modes These modes can be changed in two ways Press the push button and wait for at least one second Set database register 300 The default setting is 0 which allows you to change the display mode with the push button By setting register 300 to 1 display mode 1 is selected and by setting it to 2 display mode 2 is selected Reset the DAU to make the change valid see section 4 3 5
43. Service Manual 308012En Ed 1 Rev D August 2010 TankRadar REX Tank Gauging System ROSEMOUNT Tank Gauging EMERSON www rosemount tg com Process Management TankRadar REX Service manual First edition Rev D Copyright O August 2010 Rosemount Tank Radar AB a ROSEMOUNT lt Tank Gauging EMERSON www rosemount tg com Process Management Copyright August 2010 Rosemount Tank Radar AB The contents descriptions and specifications within this manual is subject to change without notice Rosemount Tank Radar AB accepts no responsibility for any errors that may appear in this manual Trademarks Rosemount and the Rosemount logotype are trademarks of Rosemount Inc TankRadar is a trademark of Rosemount Tank Radar AB HART is a trademark of HART Communication Foundation Modbus is a trademark of Modicon Pentium is a trademark of Intel Corporation Windows NT is a trademark of Microsoft Corporation Viton is a trademark of Du Pont Performance Elastomers Spare Parts Any substitution of non recognized spare parts may jeopardize safety Repair e g substitution of components etc may also jeopardize safety and is under no circumstances allowed Rosemount Tank Radar AB will not take any responsibility for faults accidents etc caused by non recognized spare parts or any repair which is not made by Rosemount Tank Radar AB Specific FC
44. T slaves A maximum of 3 Hart slaves can be connected to the Rex gauge in multidrop configuration If only on HART slave is connected and the short address 0 current mode is supported With three HART slaves connected short address 1 3 must be used and the slave current is parked at 4 mA The 250 2 resistance is needed for HART communication only 4 33 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Software configuration HART devices 1 Select the desired Rex device icon in the WinSetup workspace window 2 Click the right mouse button and choose the Properties option 3 Select the Configuration tab 4 Click the HART devices button and configure the HART slaves This window is used only to add a description about the connected HART slaves w REX ATG Hart Devices Configuration LT 1 Hart Device 1 Description Unit IA Hart Device 2 Description Unit Hart Device 3 Description Unit OF Cancel Apply Help For further information on how to configure the HART slaves see WinSetup Reference Manual 4 34 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 1 12 Relay Output You can use two relay ports if the optional Relay Output Card ROC is installed Different transmitter variables can be chosen to trigger the relay to change state Figure 4 11 Connecting the relay por
45. TankRadar L 2 Data Acquisition Unit Type DAU 2130 Figure 4 32 DAU LCD Display Error indication There are two alternatives to indicate an error Alt 1 the corresponding value is flashing on the screen Alt 2 a blinking Err 4 61 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Display mode 0 The following values are shown Only the values for which the DAU has been configured are shown The sequence is repeated continuously Level L for metric decimal colons for Average C for Celsius or F for Fahrenheit One current The specific channel is selected in the input database channel Digital input The digital input values are shown high values when the connected device is open not grounding 1 They are shown low when it is closed grounding 0 Each vertical segment corresponds to an input Relay The lower segment is shown when the output relay is in its normal position inactivated control The upper section is shown when the relay is in its activated position If the relay feedback does not match relay control this will be shown with a sign like this Dr Oa If there is an error System sta See Chapter Troubleshooting for more E00030 tus information 4 62 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Display mode 1 The following seque
46. The DAU controls the installed hardware based on the information stored in the database and sends error reports if requested data is not available due to hardware failure Field Bus Serial out A EEPR Temperature Choose OM Sensors sensor hen Sur configu configuration ration EEPROM Programming Switch rite enable inhibit current inputs DAU Current inputs Software BREE Local display Current data Read Status Relay status Choose Control Rela frequency inputs Frequency Frequency Inputs Figure 3 19 The DAU software handles several processes Digital Status Status 3 26 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 3 3 7 3 3 8 Chapter 3 Device Description Database Registers The DAU s database is stored in a nonvolatile memory it will retain its contents even if the power is turned off a serial EEPROM The database is copied to a part of RAM that acts as a Shadow RAM in order to increase performance when accessing the database The database contains tank specific values like the height of the temperature sensors At start up the software determines whether it was a power on or a reset from the Watchdog At power on it tests the checksum of the program stored in the EPROM and runs a test of the entire RAM If any faults are found these are flagged in status registers Then the checksum in the database is tested If it is OK the data base is loaded into the shadow RAM
47. a A A Gow im Ales nb dy God Ge Gos eed Se Bias 4 1 CMON el os esco ia dd aa a o 3 5 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Index August 2010 EICCHOMICS cto nea nie 5 oo Gee a RE E 3 23 4 46 Exchanging the Transmitter Head Electronics 00006 4 10 EXDIOSIONPlOO erica ais beatae dct enn id 2 2 External Sensors Local DISDIAN sto Seo Se Su wha ar eb oa Ga ee see weed een oe 3 27 External serial communication error 0 0 0 0 aaea eee 4 65 F Fast High Accuracy Signal Technique 0 000 cee eee 3 6 FDI sath rw ae is ee Ge ed Aon eee han ee 1 3 Operation front panel 0 0 0 0 0 ee eee 4 67 OWS SUD Wap co id barre wena Sta eter etapa cada ear 4 67 FCC Configuration for Analog Output 0 0 0 cee ee eee 4 25 FONDOS smc rd radiate ras Bae bach is bd aes GD a 3 19 FEUDO OAOA sarria a si ee ere ee ee Ome 4 48 PO SOMWAl Ors ave ene eas we od ae he See a we CR ee ee 3 20 FFT Fast Fourier Transformation 0 0 0000 eee ee eee 3 5 Field Communication Card 0 0 0 cc ee ee eee 3 8 Flammable materials o docs aa a 2 1 FMCW Frequency Modulated Continuous Wave method 3 5 Freeze CUMENE curra nd e a ia a 4 31 FUSES apio mada pio rr o ba odio ant eee 4 44 G Group and Ficld BuUS PONS m errena 2 twa seeds wae a eee eae ees Bad 4 43 H EAC TADS se mon draicl dido Gece eer bw th ne dio eee a oa 5 4 Plane CIDDING 83226225 A A AS a 5 4 Haraware INS
48. ank Radar Rex August 2010 Chapter 1 System Description The basic parts of the TankRadar Rex system are The Radar Tank Gauge RTG is an intelligent explosion protected instrument for measuring the level of a product inside a tank Four different Tank Connection Units can be attached in order to satisfy a variety of different applications The Data Acquisition Unit DAU is a local readout connection unit for use with the TankRadar Rex tank gauging system The DAU is used for connection of temperature sensors when more inputs outputs are required than is available in the Rex Gauge The Field Communication Unit FCU acts as a gateway and data concentrator between the Group Bus and the Field Bus Each FCU can have a total of 32 RTGs and 32 DAUs connected to it The Field Bus Modem FBM acts as a converter between USB or RS 232C and the TRL 2 Bus It is used for connecting a PC with TankMaster to the TRL 2 Bus e The Remote Display Unit RDU 40 is a display unit for present ing calculated and measured data from the Rex gauge such as level average temperature volume signal strength etc e The TankMaster is a software package for installation and config uration of level gauging equipment manufactured by Rosemount The TankMaster program package provides powerful and easy to use tools for installation and configuration of level gauging devices 1 3 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 1
49. ata to ATG Cancel Help Before any data is entered the Calibrate window is empty Make sure that the Tank Reference Height displayed in the lower left corner is correct To adjust the Tank Reference Height select the transmitter icon in the WinSetup workspace click the right mouse button and choose the Properties Tank Distances option 2 Click the Calibration Data button je Calibration Data Hand Dipped Level mm SAAB Level mm Delta Enable Date Time Operator pe 1 fl 1 EE J926 2 aliz 2109 3 K 3 11978 11975 3 K 4 16103 16101 2 X 5 Ol E Ol F Ol B O NOTE The tank should be measured at minimum 4 different intervals 20 40 60 and 80 of the tank height Save calibration data in PC database Refresh E Cancel Help 3 Enter hand dipped level values and the corresponding levels measured by the transmitter It is recommended that the hand dipped levels are based on the average value of three consecutive measurements within 1 mm For further information see 5 3 2 Hand dipping Note Measurement unit mm is used in the Calibration Data window 5 5 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 5 Calibration August 2010 4 Click the Refresh button Now WinSetup calculates the deviations between hand dipped and measured levels Click the Save Calibration Data in PC Database button in order to save the entered values and return to the Calibration window g
50. ation Distance based on fitting a straight line to the deviations between hand dipped levels and levels measured by the transmitter For the 3950 still pipe gauge the calibration function is specially suitable since a minor adjustment of the Scale Factor is often necessary The radar propagation velocity is dependent on the inner diameter of the still pipe and the Scale Factor parameter is used to adjust the transmitter to take this effect into account Since the average diameter is often difficult to determine accurately a calibration is often needed Procedure The adjustment process includes the following steps 1 Recording the hand dipped ullage values and the corresponding RTG level values 2 Entering the hand dipped levels and the RTG level values into WinSetup 3 Inspect the resulting calibration graph and if necessary exclude measurement points which should not be used in the adjustment calculation Required information Make sure that the following information is available when you intend to use the RTG Adjustment function in TankMaster WinSetup A list of hand dipped ullage values A list of RTG level values corresponding to the hand dipped ullage level values 5 3 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 5 Calibration August 2010 5 3 2 Hand dipping Staff 5 4 Only one person should perform the manual ullage measurements in order to guarantee good repeatability between measur
51. aulty Ing incorrect Power supply faulty Incorrect correspondence between current and displayed value 6 4 Service Manual 308012En Ed 1 Rev D August 2010 ACTION Check device Connect a resistance and check the measured value Measure current lf there is more than one current input then the power supply is multiplexed There is no continuous current in that case Check scaling configuration of inputs Service Manual 308012En Ed 1 Rev D August 2010 DAU Display E4q4uda E 4000 Eedi EY4000 E ugda EQuudo Ed 000 Ede000 FARE CAUSE System O No detected error System 1 EEPROM program error System 2 EEPROM database error System 4 RAM error System 3 5 6 or 7 combinations of errors above Codes added together External serial communication error O No detected error External serial communication 1 Communication with master lost External serial communication error 2 Communication with RTG lost External serial communication error 3 Combination of the errors above Rosemount Tank Radar Rex Chapter 6 Troubleshooting ACTION No action required Restart the DAU Exchange the EEPROM Restart the DAU Exchange PCB DMB for Slave DAU or DXB for Independent DAU Restart the D
52. ce Programming window is opened Start Device Programming Statistics Device Blocks Total Blocks Sent Program Time Start Programming Abort Close l Make sure the devices are properly prepared for reprogramming and click the Start Programming button to activate the programming pro cess Response the programming is started Comment It may take up to 2 minutes to download a flash program A maximum of 25 RTGs can be programmed for one FCU If more RTGs are connected the programming must be performed in two steps When programming is performed via a FCU only one Group Bus port may be used The FCU must be restarted prior to the programming of the RTGs Update the TankMaster installation by copying the Rex ini files for TankMaster that correspond to the new Rex software version to the folder where TankMaster is installed For example The Rex ini file is copied to the Saab Server folder The other ini files for example Rex_1E4 ini are copied to the Saab Shared folder When new application software has been downloaded the actual program version does not correspond to the text on the label on top of the EEPROM Service Manual 308012En Ed 1 Rev D August 2010 Changing EEPROM Note Make sure that power is turned off Rosemount Tank Radar Rex Chapter 4 Service Check if there is any screw that is sealed Contact Rose mount Tank Gauging before breaking the seal if warranty i
53. communication Wrong file used for programming TankMaster configuration incor rect Power supply to FBM insufficient Incorrect cables used Field Communication Unit faulty Bad connection of cables Short cables between FBM and PC Cable dimensions are insufficient No contact with RTG Rosemount Tank Radar Rex Chapter 6 Troubleshooting ACTION Check signal amplitude Check for foam on product sur face Check inclination of RTG see Installation Manual Clean antenna Check for waves on product sur face Disturbing echo may be present Restart the RTG Check if level is near empty tank Check the still pipe drawings Check amplitude of echo Should be 1000 3000 mV Restart the RTG Check that the surface of the prod uct is calm no mixer Check installation drawings and Installation Manual Check the communication to the RTG in question Check that correct diskette is used Check that correct disk drive is used Check that correct file is used with name TH lt date gt cry Check configuration Connect external power supply Use a single twisted shielded pair of wires Check LEDs on the field bus ports and the group bus ports Check connection of cables Check termination switch see 4 4 2 Check gain switch see 4 4 2 See previous pages 6 3 Rosemount Tank Radar Rex Chapter 6 Troubleshooting SYMPTOM CAUSE Current input read Connected device f
54. displayed as Level 0 If you set the C distance 0 measurements below the Zero Level will not be approved e the RTG will report an invalid level Calibration Distance is used for calibration of the RTG The Hold Off Distance also referred to as Upper Fil ter Margin defines how close to the RTG Reference Point measurements are accepted Normally this parameter should not be changed The Hold Off Distance may be increased if for example there are disturbing echoes from the tank nozzle 3 15 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 1 9 Tank Geometry The following parameters are used for tank geometry configuration of a Rex transmitter Tank Reference Point RTG Ref Distance G RTG Reference Point RTG Reference Point Tank Ullage Hold Off distance See es oe ele ee A RTG Ullage RTG Reference Point Tank Reference Height R Level Dipping Datum Point Zero Level Min Level 7 77575775 Distance C Figure 3 12 Tank geometry See chapter 3 1 8 for information on the various tank geometry parameters See also the TankMaster WinSetup Reference Manual for information on how to configure a Rex level gauge Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 3 Device Description 3 1 10 Software Description The Rex transmitter contains software which controls measurement communication etc Each program can be
55. e size product sampling or verification hand dips Figure 3 3 RTG 3950 3 3 Rosemount Tank Radar Rex Chapter 3 Device Description 3 4 LPN LNG Gauge RTG 3960 The RTG 3960 is designed for level measurement in LPG and LNG tanks A 4 in still pipe is used as a wave guide for the measurement It prevents a wavy or boiling surface from disturbing the measurement Radar signals are transmitted inside the pipe towards the surface The pressure sealing is a quarts window approved for use in pressure vessels As option the gauge can also be equipped with a fire proof block valve and a vapor space pressure sensor The LPG LNG Gauge is available in three different versions a 150 PSI version a 300 PSI version and a 600 PSI version The reference pin function enables verification of measurement without opening the tank There is a reference pin at the top of the still pipe and a calibration ring at the bottom By setting the gauge into test mode it measures against the reference pin and the calibration ring and compares with the actual distances stored during the transmitter configuration Service Manual 308012En Ed 1 Rev D August 2010 Figure 3 4 RIG 3960 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 3 1 3 At Chapter 3 Device Description Measurement principle By using FMCW Frequency Modulated Continuous Wave method Rex transmits a
56. e Calibrate LT 8 EI o Ditt L mm Tank Reference Calibration Distance ay A Old 0 0660 m Hew 0 0640 m ibrati e wrie new calibration data to ara Cancel Help 5 The Calibration window displays a straight line fitted through measure ment points representing the difference between hand dipped level val ues and values measured by the RTG For still pipe antennas a sloping line is displayed otherwise the line is horizontal The slope is due to the linear impact from the still pipe on the microwave velocity of propagation Check that the line fits well to the measurement points If a point deviates significantly from the line it can be excluded from the calculations by opening the Calibration Data window click the Calibration Data button and deselecting the corresponding check box in the Enable column Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 5 Calibration 6 Click the Write new calibration data to RTG button in order to save the current calibration data Note By clicking the Write new calibration data to RTG button the Rosemount Level values in the Calibration Data window are recalculated and the old Calibration Data is replaced Now you can check the calibration result by opening the Calibration window again a Calibrate LT 8 Ea Ditt L mm Tank Reference Calibration Distance Height fans Calibration Data wrie new calibration data to ATG Cancel Help
57. e Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 3 Data Acquisition Unit DAU 3 3 1 Overview The Data Acquisition Unit DAU is a complement to the Radar Tank Gauge y DISPLAY MODE Figure 3 15 The DAU The DAU is equipped with an interface for temperature measurement 3 3 2 Data Acquisition Unit DAU The DAU is intrinsically safe and is connected to the Radar Tank Gauge on the same tank lt receives its power supply and communicates via the Barrier Unit Card in the Radar Tank Gauge DISPLAY MODE EEx ia II C T4 Tamb 40 to 65 C BASEEFAEx91C2069 Umax in 28 VDC Wmax in 1 3 W Imas in 394 mADC Ceq 0 Leq 0 o Cable inlets Figure 3 16 DAU 3 22 Service Manual 308012En Ed 1 Rev D August 2010 3 3 3 Rosemount Tank Radar Rex Chapter 3 Device Description Electronics The DAU s main circuit board is called DMB DAU Minimum Board In Figure 3 17 the block diagram of the DAU is shown RTG Field power supply Bus for DAU sindul 00L 1d ES CODE DATA EEPROM DATABASE Figure 3 17 Block diagram of the Data Acquisition Unit 3 23 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 3 4 Temperature Measurement 3 24 Temperature sensors Measuring the product temperature is necessary for correct inventory calculations Up to 14 te
58. e assignee es ae a gi was Bee aati Dr neces 4 37 Setting the temperature measurement range 00 eee ees 4 54 Signal Processing Card anaa cc eee 3 8 Signal to NOISE Rato suas het ee eet ei ad ee howe ey 3 8 Slave Data Acquisition Unit 0 0 0 ee ee 3 22 SOltWare COMIGUIALION sociedades 4 51 Analog INPUTS 2 2 Acco ern a ed te ale A ane oh ted od wot 4 22 Analog OUlIDUIS sustraer rta eas 4 29 Relay OUIDUIS us IA eee eee ene oe eh eee eS 4 37 Spare DAMS inca thaw sheared a eee ks oe a hee ald ke Ree 7 1 Suppressing error indication 0 0 ee ee eee 4 58 SWIC Delay cos rana Send ce ee Ne aeons coded sees ad ones 4 38 System configuration DAU AdE SS e ranita Bone ee gies eat geen erat oes So eee ee oe E 3 14 RG Gd0GCSS siria atra been taboo teens dare debi 3 14 System DESCAPION cians oe ted ee ae eS Oe ee RRS oes oe ee eee aud 1 1 Data ACGUISITION UNG pia She es ag deste ah age nio 1 3 Field BUS MIOS serra dw BER al Bo ed RSG Ob he BE e ia 1 3 Field Communication Unit naaa aaa ees 1 3 Radar lank Gauge secos a odd ad cee eee a a PE bh dada ewnd 1 3 Remote Display Unit carrirr riada da abd hood SOS eu Naess 1 3 TAaNKIVIGSICR cuarenta Sead ae oe ea Cece teeth ear ues dwar 1 3 SYSICMN CMO maras Aa wd swede da she Seow Nees 4 65 T Tank Connection Unit 0 0 0 0 ce ee eee eee 3 1 Tank Dimensions Calibration Distance 0 0 ee eee 3 15 FOG ODSA E iento drid dansa 3 15 Minim
59. ements Hand dip tape Use only one tape for the calibration The tape should be made of steel and calibrated by an approved testing institute It must also be free from bends and kinks The thermal expansion factor and calibration temperature shall also be provided Manual dip hatch A dip hatch should be available close to the level gauge If the dip hatch is far away from the level gauge differences in roof movements may result in large errors Procedure Follow these instructions when you make hand dip measurements hand dip until you obtain three consecutive readings within 1 mm correct the tape according to the calibration record e note the hand dipped ullage and the RTG level reading simultane ously Do not calibrate when the tank is emptying or filling agitators are running when there are windy conditions e when there is foam on the surface Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 5 Calibration 5 3 3 Entering calibration data 1 Select the transmitter to be calibrated in the workspace window and choose Calibrate from the Service Devices menu or click the right mouse button and choose Calibrate W Calibrate LT amp Ea os Ditt L mm Tank Reference Calibration Distance Esmas Esler Tank Reference Height 0 0720 3593 796 m Height p 200000 m oi m Mew m ola ppm New pp Calibration Data write new calibration d
60. ent unauthorized changes to the data in the EPROM The switch can be locked in the write inhibit position by securing a locking plate with a wire through the clevis pins see Figure 4 18 The reset switch can be used to restart the CPU of the FCU The database in the EPROM remains unchanged by a reset If the watch dog LED was lit before the reset it is switched off by the reset Reset switch Watch Dog Write Inhibit o e Write Enable Figure 4 18 Write protection and reset switches in the FCU 4 45 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 2 6 Electronics The main board of the Field Communication Unit is the FCP board Field Communication Processor See Figure 4 19 and Figure 4 21 There are a number of LEDs on the FCP board There are green LEDs for incoming signals and yellow LEDs for outgoing signals There is a red LED indicating watch dog time out and CPU reset When the watchdog LED is lit it indicates that the CPU has been reset due to a watchdog time out and not a dip in the supply voltage There is a green LED to indicate that there is power on the FCU H13 Watchdog H14 Power Figure 4 19 LEDs on the FCP board in the FCU Table 4 2 Summary of LED indications Serial Group Group Field Field communication Bus 1 Bus 2 Bus 1 Bus 2 port Green LED Serial data H3 H5
61. erence Adapter 1 138 50 for temperature range 50 to 125 C Hi Reference Adapter 2 175 84 Q for temperature range 50 to 300 C Hi Reference Adapter 3 24 90 for temperature range 200 to 150 C Field Communication Unit FCU FCU PC board FCM board Field Bus Modem FCBM FBM 2171 FBM cable FBM DC power supply Fuses Fuse THE 5 pcs Fuse FCU 5 pcs Fuse FBM 9150072 551 9150072 561 9150072 591 9240002 512 9240002 541 9240003 721 9240003 722 9240003 723 9240002 574 9240002 701 9240002 633 6853442 682 6853496 240 0980240 013 6853472 017 6853389 084 1 1 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 7 Spare Parts August 2010 7 2 Service Manual 308012En Ed 1 Rev D August 2010 Rosemount Tank Radar Rex Chapter 8 List of Drawings 8 List of Drawings Mechanical Installation Horn Antenna Gauge RTG 3920 Parabolic Antenna Gauge RTG 3930 Parabolic Antenna Gauge RTG 3930 P440 Welding of T38 W Flange Ball T30 RTG 3935 EES Still pipe Array Antenna RTG 3950 fixed Still pipe Array Antenna RTG 3950 inclined LPG LNG Gauge 3960 Reference pin to still pipe Reflector kit LPG still pipe Reflector kit LPG still pipe Alt B Reflector kit LPG still pipe Alt A Recommended still pipes for Rosemount Radar Installation Drawing FBM 2180 sheet 3 DIN rail Installation Drawing FBM 2180 sheet 4 wall mounting Dimensional drawing FCU 2160 Mechanical Installati
62. esired device icon in the TankMaster WinSetup workspace window and choose the Upload database Save Database to File option wW Saab TankMaster WinSetup File View Semice Tools Help w i S 5 0 x a B Network Connections El M This Workstation EE Devices Upload Database Uninstall Save Database to File a Upload Database View Trp B View Holding Registers Restart Prograrn Calibrate Manual Control Relay 1 Manual Control Relay 2 Hart Devices Status User Defined Linearization Table User Defined Formula LPG Setup Hybrid Setup Enraf Emulation Properties mA For further information on how to loading and saving database registers see TankMaster WinSetup Reference Manual 4 3 Save Database to file Rosemount Tank Radar Rex Service Manual 308012En Ed 1 Rev D Chapter 4 Service August 2010 Note 4 4 w View Holding Registers LT 1 ersion 1 D2 Search for Show Values in Predefined Dec la All o Hex 4 1 4 Start Register Eno CmD Default Database Command 65510 42945967295 A A A A A A A A A Read Apply Close Help Name 4 5 6 Loading the default database The Default Database is the original factory setting for the RTG Database TankMaster Win Setup offers the option to load the Default Database This can be useful if for example you want to try new database setti
63. exer There is an RTD multiplexer for the multiplexing of signals from the Resistance Temperature Detectors RTDs See Figure 3 18 Channel 0 is connected to a 100 W precision reference resistor 0 01 accuracy located on the DMB Channel 15 is also connected to an externalreference resistor It is connected to positions 43 45 on the X21 terminal see chapter 10 5 Depending on which temperature range that has been selected one out of three reference resistors must be chosen and connected See also the list Spare Parts on page 7 1 2 x 16 channel demultiplexer Current Source 1 Current Source 2 Channel Select Channel 0 is used with an internal reference resistor Channel 15 is used with an external reference resistor 2 x 16 channel demultiplexer Differential Amplifier Pt 100 sensor Ground Figure 3 18 RTD Multiplexer 3 25 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 3 6 DAU Software The software in the DAU operates in the context shown in Figure 3 19 The software is made up of various modules called tasks The tasks are running with the following priorities Task 1 Timer Task 2 External communication Task 3 Internal communication Task 4 Commands decoding and handling Task 5 Background tasks The TIMER task is running at the highest priority so that the communication cannot interfere with the measuring of a sensor
64. function requires the 2 pin connector cable to be connected to X21 on the MB for further information see 4 1 10 Figure 4 1 Transmitter Head Electronic connections 4 11 Rosemount Tank Radar Rex Chapter 4 Service 3 Service Manual 308012En Ed 1 Rev D August 2010 Make sure that the PTFE plugs are clean Lower the THE Make sure that the cables are not stuck between the THE and the base of the enclosure The THE must rest firmly on the base so that there is no gap for the microwaves to bridge Tighten screws on the bar to secure the THE Replace the cover Check that con tact surfaces on the transmitter housing and cover are clean Tighten the screws Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 1 7 Chapter 4 Service Write protection Metrological Seal A switch on the FCC board can be used to prevent unauthorized changes in the RTG database The switch can be sealed in the write inhibit position by using a special plastic cover If there are problems writing to the database EEPROM then check the setting of the Metrological Seal How to write protect the EEPROM 1 Check if there is any screw that is sealed Contact Rosemount Tank Gauging before breaking the seal if warranty is still valid Completely remove the seal so that it does not damage the threads Loosen the screws and remove the cover 2 Remove the PCB locking from the Transmitter Head and remove
65. g In Analog out A Temperature Temp Temp Relay Out HART sensors sensors Figure 1 1 Example of a small TankRadar Rex System 1 1 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 1 System Description August 2010 Report Alarm Log TankMaster Printer Printer Plant Host RS 232C Control Computer Sn To Other FCUs Non Level To Portable Hazardous BM Service PC with TankMaster DAU Parabolic An Y IN lt tenna Gauge N ap ME LT Temperature Sensors Temperature Sensors Figure 1 2 Example of a general configuration of a TankRadar Rex System All the measured data is presented to the operator by TankMaster WinOpi which in its complete version contains inventory functions A plant host computer can be connected for further processing of data All Rosemount Tank Control supplied parts for tank top mounting weigh less than 25 kg 55 Ib except for pressure flange etc for the LPG LNG Gauge This makes it possible for one man to carry the various TankRadar parts to the tank top for installation Please read the Technical Description for a more detailed description of the Rosemount TankRadar Rex system Service Manual 308012En Ed 1 Rev D Rosemount T
66. in database register 249 The default value is set to 60 seconds This is the value which specifies the time interval without contact before communication with the RTG is considered to be lost Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 4 FBM The Field Bus Modem acts as a converter between USB or RS 232C and the TRL 2 Bus The TRL 2 protocol is used for communication with Rosemount Tank Gauging equipment The Field Bus Modem may also be used to connect foreign units to the Field Bus Connecting a PC with the TankMaster software to the TRL 2 bus requires a Field Bus Modem model 2180 4 4 1 Power Supply Use adapter 90 264 V ac 9 V dc 1 5 A for RS232 communication DO NOT use external power supply when the modem is connected to the USB port The USB interface itself supports power to the FBM2180 modem 4 4 2 Operation front panel The FBM 2180 front LEDs show information on power supply communication status and communication interface The Termination switch is used if there are extremely short cables between the transmitter and the modem The Gain switch is set to Lo by default This setting is sufficient in most cases The Hi Gain setting may be used if cable dimensions are insufficient resulting in a heavily damped communication signal LEDs for external power Gain switch Termination switch and communication Lo GAIN Hi On TERM Off C ROSEMOUNT Tank
67. ion 5 Calibration 5 1 Introduction Normally a minor adjustment of the Calibration Distance is needed in order to achieve agreement between measured and actual product level For TRL 2 transmitters the Tank Connection Length TCL is adjusted A small offset can for example result from deviations between the actual tank height and the value stored in the transmitter database or from differences between various RTG microwave units and antennas The calibration should be performed once at the final commissioning and does not need to be repeated unless tank conditions are altered You can choose to manually adjust the Calibration Distance or you can use the Calibrate function in WinSetup for automatic adjustment 5 2 Manually adjusting the Calibration Distance The Calibration Distance can be manually adjusted in order to compensate for differences between different RTG microwave units and different antennas For TRL 2 2900 transmitters the corresponding adjustment is done by changing the TCL parameter For Rex transmitters the TCL is never adjusted except when non standard antennas are used If there is a deviation between hand dipped and measured levels you may calculate a new Calibration Distance value according to the formula New Calibration Distance Old Calibration Distance AL where AL observed level hand dip transmitter level reading The same formula applies for TRL 2 transmitters if the Calibration Distance i
68. ions as well Several registers are used for controlling the RTG gauging process For example there are registers which specify the measurement range and registers which determine the lowest amplitude to be considered as a valid radar echo 3 13 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 Input Register Measured data is continuously stored in the Input registers of DAUs RTGs and FCUs By viewing the contents of device input registers you can check that the device works properly The following summary lists some frequently referred database registers Correction values Unit ID Every RTG DAU and FCU has a unique Unit ID which is used to identify the unit when installing a Rex system System configuration RTG address The assigned Modbus slave address for the RTG Default value 246 DAU address The assigned Modbus slave address for the associ ated DAU Default value 247 FCU address The assigned Modbus slave address for the associ ated FCU Default value 245 Tank Connec The electrical distance from the Transmitter Head tion Length Electronics to the RTG Reference Point the electri TCL cal distance is not equal to the physical distance The TCL value is different for different gauge types antennas When configuring a Rex transmitter in TankMaster WinSetup you can choose between predefined or user defined antennas see TankMas ter WinSetup Reference
69. l values correct Incorrect database constants RTG locked on disturbing echo Metrological Seal in write inhibit position Service Manual 308012En Ed 1 Rev D August 2010 ACTION Put switch in write enable position Measure resistance on tempera ture sensor wires Check connection of temperature sensors to terminal Lowest sen sor to lowest number on terminal Measure resistance between sig nal wire and ground must be gt 5 MO Measure resistance Check correspondence between measuring range and type of sen sor Check jumpers for temperature range in DAU Check configured measuring range Check configured number of tem perature elements Check the configured position of the temperature elements Check the position of the tempera ture elements Check the level of the product in the tank Check tank distances in the RTG configuration Hand dip to verify the level Initiate new echo search Look for objects in the tank creat ing disturbing echoes Put switch in write enable position Service Manual 308012En Ed 1 Rev D August 2010 SYMPTOM Downloading of program to RTG impossible ComFail occurs CAUSE Echo amplitude below noise threshold Still Pipe Gauge Amplitude of approximately 20 000 mV or more Parabolic or Cone Antenna Gauge Disturbing echo with strength above the noise threshold Varying amplitudes Mechanically incorrect installation Faulty
70. land of the RDU 40 Check the gasket and put the locking device for the weather protection hatch in position when remounting the RDU cover Tighten all six screws firmly Mount the RDU 40 with the four M4 screws Distances between the screws are 60 mm and 68 mm according to the back of the RDU 40 See the RDU 40 User s Guide Ref no 308010E for further information on RDU 40 installation Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 5 2 4 5 3 Chapter 4 Service Two RDU 40 connected to the same Rex lf two RDU 40 are connected to the same Rex one of them has to be configured as slave while the other is master The slave cannot be configured or controlled individually but follows the master Only the LCD contrast can be individually controlled on the slave RDU 40 To make an RDU 40 work as a slave it is necessary to move the jumper at the RDU 40 cover to position 2 see Figure 4 35 Data items 24 items are available dependent of how the Rex gauge is equipped Level Ullage Level rate e Signal strength Volume Average temperature e Temperature spot 1 6 Analog input 1 2 Vapor pressure e Observed density Free water level e Hart slave 1 3 Relay 1 2 Rosemount Tank Radar Rex Chapter 4 Service 4 72 Service Manual 308012En Ed 1 Rev D August 2010 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 5 Calibrat
71. lue that corresponds to the jumper settings In TankMaster WinSetup In the DAU configuration window click the Configure button next to the Number of Temperature Sensors field w TRL 2 DAU TT 1 Temperature Sensors Configuration Exclude from Sensor Average Sensor range Sensor Type Position Calculation peroo 14 13 00 m TF Senzor Range ll 12 00 tt E From 50C to 1250 2 fio ff User 10 00 m TF From 50 C to 125 E 2 From 200 C to 150C m a 8 7 00 m TF T Je 00 m TF E fig m D E je m D 4 E m T 3 f o a E m D ih mr OF Cancel Help Note See spare parts list for part number of reference resistors 4 55 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 3 2 Checking the Resistance Temperature Detectors Pt100 sensors spot measurement are connected with three wires each The Cu90 sensors average measurement are connected with a common ground The sensors can be checked by measuring their resistance and the surrounding temperature Then check in the tables below If the temperature derived from the table does not correspond to the actual temperature then the sensor needs to be replaced See tables and connection diagrams below See also Installation drawings on page 8 1 for connection of the temperature sensors Pt100 Cu90 79 05 1 90 124 76 79 08 1 1 1 EIA 20 8286 o 147 l 1 50 5025 w 43 90 o parn
72. m RTG No contact with unit Write protection switch in wrong position Rosemount Tank Radar Rex Chapter 6 Troubleshooting ACTION Check TRL 2 bus wires Check and correct address and Unit ID in TankMaster Check LEDs in FCU if a FCU is included Check address of unit and check communication port for correla tion Check that all signals of the RS 232 are connected according to installation drawing Check that unit is connected to the correct field bus port on the FCU Check dress of unit and check communication port for correla tion Exchange FCM cards to identify the faulty card Replace FBM Check the items above Check the items above Check the RTG configuration in TankMaster Check power supply by measuring the voltage between pins 6 and 7 on DAU connector The voltage should be about 5 5 V Check Bar rier board in Electronic Unit in RTG Check unit according to the previ ous page Put switch in write enable position 6 1 Rosemount Tank Radar Rex Chapter 6 Troubleshooting SYMPTOM Not possible to write to RTG Temperature measurement incorrect Incorrect reading of level 6 2 CAUSE Metrological Seal in Write inhibit position Temperature sensor incorrectly connected Temperature sensor with ground failure Short circuited temperature sen Sor Measured value outside the mea suring range Faulty configuration Wrong average value but individ ua
73. me data was stored in both FCUs For further information on FCU Installation Procedure see WinSetup Reference Manual 4 53 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 3 DAU 4 3 1 Setting the temperature measurement range Do the following to set the measuring range of the temperature sensors 1 Connect the reference resistor corresponding to the desired measure ment range to channel 15 The X21 terminal Connect temperature sensors DAU Connect Reference Resistor to terminals 43 44 and 45 Figure 4 25 Reference Resistor 2 Set the jumpers X1 X2 and X3 on the DAU s circuit board in the correct positions for the desired measurement range The jumpers are set according to Table 4 3 See also Figure 4 26 The default setting is from 50 C to 125 C for the Pt 100 sensor X1 OPEN X2 OPEN Figure 4 26 Jumper settings for temperature range 50 to 125 C 4 54 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Table 4 3 Temperature Range Temperature X1 X2 X3 Reference Range Resistor Q Pt 100 Cu 90 50 125 C OPEN OPEN CLOSED 138 50 50 300 C CLOSED CLOSED CLOSED 175 84 200 150 C CLOSED CLOSED OPEN 24 90 Set the database register that specifies the temperature range to the va
74. meter 9 5 Rosemount Tank Radar Rex Chapter 9 Technical Data 9 6 9 6 FCU 2160 Ambient operating temperature Power Supply Group bus interface Field bus interface Explosion protection Number of tanks per FCU Service Manual 308012En Ed 1 Rev D August 2010 40 C to 70 C 40 F to 158 F 115 or 230 VAC 10 to 15 50 60 Hz max 10 W TRL 2 Bus RS 232 or RS 485 Modbus based protocol TRL 2 Bus Max 8 units on one port None Max 32 max 8 per field bus is recom mended Service Manual 308012En Ed 1 Rev D August 2010 9 7 DAU 2100 Ambient operating temperature Sensor elements Number of sensor elements Temperature measuring range Explosion protection Power Supply Field bus Rosemount Tank Radar Rex Chapter 9 Technical Data 40 C to 70 C 40 F to 158 F Pt 100 single or multispot Max 14 per DAU Range 1 50 C to 125 C 58 F to 257 F Range 2 50 C to 300 C 58 F to 572 F Range 3 200 C to 150 C 330 F to 302 F Il 1G EEx ia IIB T4 ATEX and Class 1 Div Groups C and D UL913 USA Intrinsically safe supply from Radar Tank Gauge Intrinsically safe local line from Radar Tank Gauge 9 7 Rosemount Tank Radar Rex Chapter 9 Technical Data 9 8 9 8 RDU 40 Ambient temperature Hazardous locations certifications FM Max cable length Cable requirement Material housing Dimensions Weight Ing
75. mode 1 if dis play is included for blinking value of the faulty sensor Exchange the precision refer ence resistance If problem per sists then exchange PCB DMB for Slave DAU or DXB for Inde pendent DAU Check if product level is below the lowest functioning non blocked sensor Check that DAU receives a level from the associated RTG No action required See items under Current input reading incorrect Service Manual 308012En Ed 1 Rev D August 2010 DAU Display CAUSE Current input error p for pres ELEC 2 erat cattraton enor Current input error p for pres ETE Si vane m atieastone vane Same cause as 1 above Output error Independent DAU E Relay feedback does not match D9 FP relay control Rosemount Tank Radar Rex Chapter 6 Troubleshooting ACTION Exchange PCB DMB for Slave DAU or DXB for Independent DAU See items under Current input reading incorrect Exchange relay card DRM 6 7 Rosemount Tank Radar Rex Chapter 6 Troubleshooting 6 8 Service Manual 308012En Ed 1 Rev D August 2010 Service Manual 308012En Ed 1 Rev D August 2010 Rosemount Tank Radar Rex Chapter 7 Spare Parts 7 Spare Parts Radar Tank Gauge Transmitter Interface Card TIC Temperature Multiplexing Card TMC Relay Output Card ROC Data Acquisition Unit DAU DAU DMB board Display board Precision Reference Resistors Hi Ref
76. mperature sensors can be connected to each Data Acquisition Unit The temperature elements are placed in a tube which is anchored to the bottom of the tank Either Pt 100 spot element or Cu90 average sensor temperature sensors can be used By using the Pt100 spot sensors a profile of the temperature at various tank levels is obtained as well as the average temperature of the liquid The Cu90 sensors measures the average temperature measured from the tank bottom to the product surface Reference resistors There are two reference resistors connected which are used to calibrate the voltage to frequency converter VCF feeding the DAU s microprocessor with data from the temperature sensors The internal 100 W precision reference resistor is connected to channel O of the RTD multiplexer The external reference resistor is connected to channel 15 In some cases there is a third reference resistor connected to the first free temperature sensor input Using this sensor enables the accuracy to be increased even more Database The DAU s database contains several registers for temperature measurements Temperature range and sensor type may need to be checked before operation The ratio between the two reference resistances is measured and the tolerance of the deviation from the nominal value is also stored in the database Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 3 Device Description 3 3 9 RTD Multipl
77. nce is shown when the display is in mode 1 Level See display mode i e dh i A O for explanation y Temperature sensor 1 TS If the sensor is below the surface TN ie The temperature value of Pressure sensor 1 aoe The pressure value of sensor 1 DEI p 31 The pressure value of sensor 2 Digital input values See display mode Y 7 yy O for explanation a Relay output control see display mode i y O for explanation If there is an System status See Chapter Trou error bleshooting for 1 00037 more information Temperature sensor 2 CS The temperature value of E 4 63 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 64 Display mode 2 This mode locks the display on the value which is on display at the moment The value is still sampled at its usual rate approximately every 15 seconds for a temperature sensor Press the button and hold it down Release the button when the value before the desired value is displayed For example if temperature value C5 is to be displayed then release the button when the display is showing the value of temperature C4 You can set this display mode remotely via database register 300 The default reading is level If you want to remotely change the display to other variables in display mode 2 please contact Emerson Process Management Rosemoun
78. ned to make inventory calculations directly in the gauge to be used by a DCS system or give precise inputs for tank calculations in another computer The gauge can receive and process signals from analog and digital pressure transmitters water bottom sensors etc All measured data are transmitted on the field bus and can be further processed in the control room by the TankMaster PC software or by the plants host computer DCS system Due to the high processing Capacity inventory calculations can be made by the signal processor in the gauge without any separate field computer Figure 3 10 Hybrid tank gauging combines radar and pressure mea surement to get density and mass information online The gauge calculates e Total observed volume using the tank strapping table e Mass if pressure sensor connected Observed density if pressure sensor connected e Level corrected for thermal tank wall expansion Temperature e Oil Water interface level Strapping table data downloaded from the Rosemount TankMaster PC software are resident in the gauge All data is calculated according to updated API and ISO standards The temperature calculations include API algorithms to handle elements close to the bottom The level value is software corrected for changes in tank reference height Both metric and USA UK units are supported Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August
79. ngs and then want to reload the original factory setting or when the tank conditions have been altered If error messages appear or other problems occur concerning the Database a troubleshooting is recommended before loading the Default Database The device address remains unaltered when the default database is loaded To load the default database Select the desired device icon in the TankMaster WinSetup workspace window Click the right mouse button and choose the View Holding Register option Choose the All option and type 65510 in the Start Register input field Type the desired number of registers to be displayed in the Number of Registers field and click the Read button Number of ON Register Value Unit w Expanded enum x 65512 65513 65514 65515 65516 65517 65515 65513 65520 Heset to factory setting OF Cancel Help L Ll Ll l l l l li Double click in the Value input field Select Reset _ to factory_setting from the list of options Click the Apply button Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 1 5 Installing new Transmitter Software The transmitter software is stored in flash EEPROM The software consists of boot software and application software They are both placed in the same EEPROM There are two different methods to install new Transmitter Software e Downloading Changing
80. ommunication Unit The Field Bus Process scans the slave units as a master The result of the queries is stored in the standard data registers It could also get queries from the Group Bus via the Special Command Process to be sent out on the Field Bus The results of those queries are stored in the Special Data Buffer Redundancy In order to reduce the risk of communication failure between the TankMaster and the units connected to the TRL 2 field bus two FCUs can be connected to run in parallel If one FCU fails the other one automatically takes over without any action from the operator The FCUs are connected with an extra cable allowing them to communicate The inactive FCU constantly checks if the connected FCU is active If the active FCU fails it signals to the backup FCU to take over Then the backup FCU immediately switches to an active state Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 3 2 5 Chapter 3 Device Description Connection to a PC The FCU can be connected to the PC either directly via a TRL 2 Group Bus or via the RS 232C interface The RS 232C connection can be made with 3 wires from the PC to the Field Communication Unit The cross sectional area must be at least 0 25 mm AWG 24 or similar The maximum length of the RS 232C connection is 15 m The TRL 2 bus requires a twisted and shielded pair cable with a cross sectional area of min 0 50 mm AWG 20 or similar Servic
81. on Sun Shelter Dimensional drawing DAU 2100 Electrical Installation RTG DAU AIN Relay RTG AIN Temp Relay RT G JBi DAU AIN Relay RTG JBi AIN Temp Relay Power TRL 2 Bus Connection RTG W11 X11 Relay 1 2 connection RTG W11 X11 Relay 1 connection RTG W11 X11 Analog Output Connection RTG W11 X11 9150 072 980 9150 072 981 9150 072 982 9240 003 944 9240 003 947 9150 072 983 9150 070 941 9150 070 943 9150 072 986 9150 072 922 9150 071 651 9150 072 924 9150 072 925 9240 003 987 9150 070 972 9150 070 972 9240 002 914 9240 003 930 9240 002 913 9150 072 913 9150 072 914 9150 072 911 9150 072 912 9150 072 930 9150 072 932 9150 072 933 9150 072 934 8 1 Service Manual 308012En Ed 1 Rev D August 2010 Rosemount Tank Radar Rex Chapter 8 List of Drawings 8 2 RDU DAU and Analog Input RTG W12 X12 Temp sensor connection RTG W12 X12 WBS temperature connection RTG W12 X12 Installation Drawing FBM 2180 sheet 2 USB PC FBM 2180 JB RTG PC FBM 2180 FCU FCU 2160 PC FCU RS232 FCU in PU2 PC FCU RS485 PC RS232 485 FCU FCU PS12 LABKO 2000 PC Fibre Modem FCU Redundant FCU connection PC Host FCU DU620 FCU DAU Cu90 DAU Pt100 3 wire DAU Pt100 with common returns DAU Pt100 3 wire WBSi w RTD DAU Pt100 3 wire WBSi w out RTD 9150 072 940 9150 072 941 9150 072 943 9150 070 972 9240 002 968 9240 002 959 9240 002 914 9240 002 905 9240 002 931 9240 002 936 9240 003
82. order to use the Analog Output function the cabling must be disconnected from the ROC board and connected to the Mother Board Jumper settings on the FCC are needed in order to configure the card for Current Loop Output active internal loop supply or passive external loop supply Note Make sure that power is turned off before opening the cover 1 Check if there is any screw that is sealed Contact Rosemount Tank Gauging before breaking the seal if warranty is still valid Completely remove the seal so that it does not damage the threads Loosen the screws and remove the cover 2 Loosen the two screws which hold the Electronic Unit 4 25 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 3 Carefully lift the Elec tronic Unit Handle the Electronic Unit care fully Be especially careful with the PTFE plug at the center of the bottom of the Elec tronic Unit 4 1 Remove the 2 pin connector from the ROC board 2 Plug the 2 pin con nector cable into the X21 connection on the Motherboard 5 Make sure that the PTFE plugs are clean Ss Lower the Electronic Ss DN Unit Check that the F i i N cables are not stuck il between the Elec tronic Unit and the base of the enclo sure The Electronic Unit must rest firmly on the base so that there is no gap for the microwaves to bridge 4 26 Service Manual 308012En Ed 1 Rev D Rosemoun
83. previous state as long as the source variable is changed only small amounts around a certain set point The principle of relay set points and hysteresis zones is shown in the figure below Note that in this case only two states are used Relay state The source value passes set point one and the relay state is changed according to the definition for Zone 1 The relay state is changed back to the Zone 2 state when the source value passes the set point as given by the hysteresis value The source value passes set point two and the relay state is changed according to the definition for Zone 3 The relay switches back to the Zone 2 relay state when the source value passes set point two as given by the corresponding hysteresis value 4 39 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 40 Manual relay control To manually switch between different relay states do the following Select a Rex gauge in the workspace window Expand All Uninstall Save Databaze to File Upload Database Mew Input Registers Mew Holding Registers Restart Program Calibrate Manual Control Relay 1 Manual Control Relay 2 Click the right mouse button and choose the Manual Control Relay option or from the Service menu choose Devices Manual Control Relay w REX RTG Manual Control Relay 1 LT 1 Ea Control Mode Disabled Manual Relay Status Alarm s
84. rabolic Antenna Gauge RTG 3930 The Parabolic Antenna Gauge RTG 3930 measures level of all types of liquids from light products to bitumen asphalt The gauge is designed for mounting on tanks with fixed roofs and has custody transfer accuracy The design of the parabolic antenna provides extreme tolerance against sticky and condensing products The narrow beam of this antenna makes it very suitable in narrow tanks with internal structures Figure 3 2 RIG 3930 3 2 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 3 Device Description The Still Pipe Gauge RTG 3950 The Still Pipe Gauge is used on tanks with still pipes and with all products suited for still pipes The gauge uses a low loss radar propagation mode which virtually eliminates the influence of the still pipe condition Measurements is made with highest accuracy even when the pipe is old rusty and covered with deposits The Still Pipe Gauge fits 5 6 8 10 and 12 pipes It can be mounted on an existing still pipe and there is no need to take the tank out of operation during installation There are two versions of RTG 3950 fixed and inclined The inclined version has a hinged hatch enabling full pip
85. red depending on what type of sensor that is used The jumpers are installed at factory and do normally not need to be changed If you need to change TMC board configuration for example if other sensor types than originally specified will be used do the following Make sure that power is turned off 1 Check if there is any screw that is sealed Contact Rose mount Tank Gauging before breaking the seal if warranty is still valid Completely remove the seal so that it does not damage the threads Loosen the screws and remove the cover 2 Remove the PCB locking from the transmitter head and remove the TIC TMC board 3 Carefully separate the TMC from the TIC board Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 Set jumpers on the TMC board to one of the following alternatives 1 6 multiple spot or average elements O 20 Vs Bea ls rEg gaei i X4 I E lt 0000000000000 0 ect __ E e 8 pin connector cable e O Figure 4 3 TMC board configured for 1 6 multiple spot or average ele i 2 fhe ments e Set three jumpers in socket X4 and one jumper in socket X5 e Connect the 8 pin connector cable to the X2 connector on the TMC board e Check that the Temperature sensors are properly connected to X12 see the Tankadar REX Installation Manual Connector X12 Figure 4 4 Connector X12 4 17 Service
86. ress protection Service Manual 308012En Ed 1 Rev D August 2010 20 C to 55 C 4 F to 130 F Il 2 G EEx ib IIC T4 ATEX Class Div Group A B C D 100 m 328 ft total length if two units are con nected to the same gauge 3 wire shielded instrument cable Min 0 5 mm AWG 20 Max 2 5 mm AWG 14 Max 14 mm 0 55 inch Min insulation thickness for each wire 0 25 mm 0 00985 inch Die casted aluminium 150 x 120 x 70 mm 6 x 4 x 3 inch 1 2 kg 2 6 Ibs IP 66 amp 67 Service Manual 308012En Ed 1 Rev D August 2010 9 9 FBM 2180 Power supply for RS 232 Cable to Host PC Explosion protection Field bus over voltage protection Field interface Computer Host inter face LED indicators Rosemount Tank Radar Rex Chapter 9 Technical Data DC 7 12 V 50 mA RS 232 3 m 10 ft USB 3 m 10 ft None Galvanic insulation and transient suppressors TRL 2 RS 232 or USB External power host connection TRL 2 transmit and receive 9 9 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 9 Technical Data August 2010 9 10 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Index Index A Alarm mode settings 0 00 ccc ee eens 4 31 Analog Processing Card escuadrones 3 8 B BNM PION sac cee ES oh a we eben E bic ete BRS Se ae 4 31 ESHA EOW o rr dato dd dirias Geta ta oe 4 31 C CANDPAUON Loera dais Bee 5 1 Galbfatlo dala
87. rmation from previous measurements 3 5 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 6 Fast High Accuracy Signal Technique FHAST To further improve measurement accuracy Rex can utilize the benefits of Rosemount s Fast High Accuracy Signal Technique Multiple Echo Tracking MET Multiple Echo Tracking is another advanced feature which provides increased resolution in tanks with disturbing objects MET facilitates the separation of disturbances from the actual product surface echo Programmable Dynamic Real Time Memory Memory Memory 0 Disturbance Echo Multiple Echo Handlin Digital Signal Processor Signal Product Level m FHAST High Accuracy Filter Figure 3 6 Signal processing schedule Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 3 Device Description 3 1 4 Transmitter Head Electronics The electronics is mounted in an exchangeable unit in the explosion proof Transmitter Head A high measurement accuracy is achieved by using digital reference circuitry and by controlling the internal temperature by an internal heater The 3900 transmitter head can be used on all types of Rex antennas A metrological seal is available to prevent unauthorized changes of database se
88. rs for 4 20 mA cur rent loops e One supply barrier for a DAU or a local display unit One signal barrier for communication with the DAU or local display unit e Signal supply connection for optional TMC Temperature Multiplexer Card TMC optional The Temperature Multiplexer Card TMC is an optional add on board which is mounted on the back of TIC TMC is used to connect up to 6 temperature sensors Both spot and average sensors are supported Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 3 1 5 Chapter 3 Device Description Write protection Metrological Seal Part of the memory space in the Electronic Unit is of EEPROM type Electrically Erasable Programmable Read Only Memory Program and database updates are possible to perform over the Field Bus without opening the Safety Enclosure A switch on the FCC board can be used to prevent unauthorized changes in the RTG database The switch can be sealed in the write inhibit position by using a special plastic cover For further information see 4 1 7 Figure 3 8 Metrological seal As an option Rex can be equipped with the TRL 2 Metrological Seal consisting of a connection rod that activates the write protection switch Figure 3 9 Optional version of Metrological Seal 3 9 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 1 6 Internal calculations TankRadar Rex is desig
89. s still valid Completely remove the seal so that it does not damage the threads Loosen the screws and remove the cover Remove the PCB locking from the THE and remove the SPC board The EEPROM is located on the SPC board and mounted in a socket 4 7 Rosemount Tank Radar Rex Chapter 4 Service Cut off corner 4 8 Service Manual 308012En Ed 1 Rev D August 2010 Remove the old EEPROM by using the IC Extractor tool Do not use a screwdriver or simi lar tools Place the new EEPROM into the socket Make sure that the cut off corner is placed in the right position Note Make sure that necessary precautions are taken in order to prevent electrostatic discharge from damaging the EEPROM Replace the SPC board PCB locking and cover Check that contact surfaces on the trans mitter housing and cover are clean Tighten the screws Turn power on Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Note Chapter 4 Service Check the Software version in TankMaster WinSetup 1 Select the desired device icon in the workspace window 2 Click the right mouse button and choose the Properties option Choose the Communication tab Now the transmitter software version is displayed in the Version field w REX ATG Properties LT 1 x Communication Configuration Tank Distances RTG Geometry Communication Pres Communication Channel ModbusMasterT Modbus
90. s changed to the TCL parameter 5 1 Rosemount Tank Radar Rex Chapter 5 Calibration Service Manual 308012En Ed 1 Rev D August 2010 To change the Calibration Distance value stored in the transmitter database 1 Start the TankMaster WinSetup program 2 Select the transmitter icon in the WinSetup workspace 3 Click the right mouse button and choose the Properties option 4 Select the RTG Geometry tab w REX ATG Properties LT 1 Ea Communication Configuration Tank Distances FTG Geometry Antenna Settings Antenna Type Tank Ref Foint Cone 3920 Tank Connection Length TCL 0 000 m Hold Off Dist IUFM o 30d a Used Hold Off 0 300 inumumLevrel Calibration Distances Calibration 0 000 m Distance Cancel Apply Help 5 Type the Calibration Distance value in the corresponding input field and click the OK button 5 2 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 5 Calibration 5 3 Using the WinSetup Calibrate function 5 3 1 The Calibration function is a tool to adjust the RTG in order to minimize the offset between actual hand dipped product levels and the corresponding values measured by the transmitter By using the Calibrate function you can optimize measurement performance over the whole measurement range from the top to the bottom of the tank The Calibration function calculates a new Calibr
91. surface with a continuously varying frequency The reflected signal is mixed with the outgoing signal resulting in a low frequency signal which is proportional to the distance to the liquid surface By using a signal processing technique based on Fast Fourier Transformation FFT a frequency spectrum of all echoes in the tank is obtained From this spectrum the surface level is extracted with high accuracy 4 1 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 1 2 Viewing and Editing database registers 4 2 Measured data is continuously stored in the Input registers of DAUs RTGs and FCUs By viewing the contents of device input registers you can check that the device works properly The Holding registers store various transmitter parameters used to control the measurement performance Most Holding registers can be edited by simply typing a new value in the appropriate Value input field Some holding registers marked grey in the Value input column can be edited in a separate window In this case you can choose from a list of options or you can change separate data bits To view edit input or holding registers of a certain device Select the desired device icon in the JankMaster WinSetup workspace window and click the right mouse button and choose the View Input Holding Registers option mM Saab TankMaster WinSetup File View Service Toole Help ow i a E
92. t 2010 Note 4 1 9 Chapter 4 Service Analog inputs Rex supports two high precision 4 20 mA analog inputs Using the analog inputs requires that the transmitter is equipped with the Transmitter Interface Card TIC Analog Input 1 may be used to connect up to 3 HART Slaves requires Multi FCC card See 4 1 11 Cc te Pressure sensor gt Water Level sensor Figure 4 7 Connection of analog input instruments to the Rex Junction Box The Analog Inputs are identified automatically by the software The TIC board must be detected before this function is enabled Analog inputs are connected to socket X12 for intrinsically safe connections in the Rex Junction Box For further information on how to connect analog inputs see the TankRadar Rex Installation Manual Analog inputs can only be enabled at factory Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 22 Software configuration Analog inputs To configure the analog input signals do the following Select the desired Rex transmitter icon in the JankMaster WinSetup workspace Click the right mouse button and choose the Properties option select the Configuration tab and click the appropriate Analog Input button w REX ATG Analog Input 1 LT 1 Ea Value Range Value at 20 m 470 000 Value at 4 m 20 000 Error Limita Display High Current
93. t Tank Gauging for instructions Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 3 9 Chapter 4 Service Local Display Error codes The type of errors displayed on the local display can be divided into the following groups e System External serial communication Internal serial communication Temperature measuring error System Errors indicate that there is an error in one of the memory circuits External serial communication error means that communication with master or RTG is lost Internal serial communication error may indicate that there is an internal bus failure Temperature measuring error may indicate that there is a defect temperature sensor or a calibration error 4 65 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Note 4 66 4 3 10 Time out settings Master communication time out The master communication time out specifies the elapsed time without contact before communication with the master is considered to be lost This value is stored in database register 188 The default value is set to 20 s The database value is given in number of ticks 255 One tick is equal to 278 us and 255 ticks is equal to 71 ms Thus the value stored in database register 188 must be multiplied with 71 ms in order to obtain the time out value in number of seconds RTG Communication time out The RTG communication time out is stored
94. t Tank Radar Rex August 2010 Chapter 4 Service 6 Tighten the two screws which hold the Electronic Unit Remove the PCB locking from the Elec tronic Unit and remove the FCC board 4 27 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 8 Check that the Multi FCC card 9150072 673 is used Set the jumpers according to Figure 4 9 below for current loop active or passive lee e e ee j O o i D000 0 G Figure 4 9 Current Loop Output settings 9 Replace the FCC board and PCB locking Check that contact surfaces on the transmitter housing and cover are clean Replace the cover and tighten the screws 4 28 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Software configuration Analog outputs You can choose various sources for the Analog Output The Upper Range value for the analog output signal is 20mA and the Lower Range value is 4 mA The following Analog Output sources measuring variables are available 1 Level Ullage Level Rate Amplitude Volume and Observed density the Upper and Lower range can be changed in the Range Values inpu
95. t field 2 RTG AvgLiqgTemp RF Head Temp DAU AvgLiqTemp Gas Pressure Liquid pressure Gas Temp LiquidTemp and Free Water Level the Upper and Lower range values can be changed in Holding Registers 2144 and 2146 There are five different alarm modes available for further information see Alarm mode settings on page 4 31 To configure the Analog Output signal do the following 1 Select the desired device icon in the WinSetup workspace window 2 Click the right mouse button choose the Properties option and select the Configuration tab 3 Click the Analog Output button w REX RTG Analog Output LT 1 A ut Source Range Values Level Upper 20 mA 20 000 m Alarm Mode Lower 4 m Freeze Current a 0 000 m Curent 15 6 m 4 29 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 30 Choose a measuring variable in the AOut Source list Set the Upper and Lower Range for the analog output signal in the Range Values input field For measuring variables that can not be edited in the Range Value input field set the Upper and Lower values in Holding Registers 2144 and 2146 For further information on how to edit Holding Registers see To view edit input or holding registers of a certain device on page 4 2 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Alarm mode settings Product level
96. tabase reload o o o ooooooooo oo 4 60 Local Display MO0CS tica vere See wee es 4 61 Local Display Error codeS o o ooooooooo 4 65 Time out settingS ii di a hooey enews 4 66 E RA 4 67 FOWEE SUPPI 2 2 Es 4 67 Operation front panel o o o o oooooooooo 4 67 FBM instead of FCU for small systems 4 68 isos dos eco cds sueltos caia Susan Betta tere 4 69 INSTAHQUO sal ei EA A e A Bt 4 69 Two RDU 40 connected to the same Rex 4 71 WALA ICIS 0 patas Dtos Vis as ta on he 4 71 Service Manual 308012En Ed 1 Rev C Rosemount TankRadar Rex August 2010 Contents 5 CALIBRATION cubero 5 1 5 1 INTRODUCTION corsarios 5 1 5 2 MANUALLY ADJUSTING THE CALIBRATION DISTANCE 5 1 53 USING THE WINSETUP CALIBRATE FUNCTION 5 3 5 3 1 Required information o ooooooooooooo o 5 3 5 3 2 Hand QIDDING poi So dee beck eee AREA 5 4 5 3 3 Entering calibration data o oooooo o 5 5 6 TROUBLESHOOTING ss 5000 dela 6 1 Ta SPARE PARIS acaricia da 7 1 8 LIST OF DRAWINGS cocoa ao 8 1 9 TECHNICAL DATA gt 0 03 barracas oda 9 1 9 1 RTS 3900 a a AA AA A a ee es 9 1 9 2 AUS IZ a ds ii RES 9 2 9 3 EI E a Oe 9 3 9 4 RETOS Desire a AAA 9 4 9 5 A A A ot oe pon Ak Seance ean tal ope ee 9 5 9 6 FC DOO ratio nda rd o ase ada per 9 6 9 7 PAUZ Y AA A O ee a ee 9 7 9 8 ADUANA aa 9 8 9 9 ESNMIZISO sce assy A A ee dere won Hee we a nee ae aaa 9 9
97. tallaliOn ves iria A A A ee 4 50 A A A E O 4 33 Ha olaVes wach wad died A oe eee eae 4 33 Hazardous areas a Gad we A E AAA es 2 1 MON GUINEA 4 31 Hom Antenna Gale urea srl ES A en ee eee es 3 1 3 2 PIVSICICSIS 244 au 4 hud ate dns bee a a a ro ds baa 4 37 Installing new transmitter software 0 0 0000 eee 4 5 Internal calulations dia A A SE EES ee ERS 3 10 GOSS VOM anu data andes dba 3 10 E 5 garira ea a stint acne dt E E de ence Re de ste dese ah aatte 3 10 MISS 2c tarta cat oe Bad eee E E ET 3 10 Observed GENS ties wa tke ie eee eae ee eae See eam tees E 3 10 Oil Water interface level 0 0 0 0 ce ee ee eee 3 10 Temperatura riada idiota 3 10 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Index Internal serial communication error anana aaa 00 ce ee es 4 65 INTIASIC S ALO siega a vicar os A ward ee ee A leat Soak Hh ah PAR A 2 1 J J mper SOUNDS ad sakai eaan bee haath eee eee be de dant ed ead 4 54 L IIS ORCNAWING St 2123 re bs eS eo eee ne ee e ee Se 8 1 Loading and Saving a device database 0 eee 4 3 Loading the default database 20 ee ee ee 4 4 Local Display Error COGS varices 4 65 OW CUNEN sn iii diel O o a ese A 4 31 LPGENG Gauge src iaa a eee es e s 3 1 LENENG GAUGE scaner ia bo a dd wa eres se aot 3 4 M WeanlaliCQO AUC sisi Ed it aes Sy ee 5 4 Manual relay control 2 0 0 0 0 0 ee ees 4 40 Master communication timeout 0 0 eee 4
98. tate selected manually Safety Reset 30 0 5 Alarm State means Not Energized and Mot Active Mormal state means Energized and Active OK Cancel Apply Help Choose Manual in the Control Mode field and click the Switch Mode button Choose a new relay state from the Select New State list and click the Apply or the OK button For further information on how to configure the Relay Output see WinSetup Reference Manual Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 2 FCU 4 2 1 Default database loading The default database can be loaded by moving the jumpers on terminals X14 and X15 The position of X14 and X15 on the FCU board is shown in Figure 4 13 Watchdog Figure 4 13 Terminals X14 and X15 on the FCU board Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 To load the default FCU database 1 Disconnect power 2 Move jumpers on socket 14 and 15 to the upper position 3 Connect power 4 Wait until watchdog lights up see Figure 4 13 5 Disconnect power 6 Replace jumpers to the lower position 7 Connect power 4 42 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 4 2 2 Group and Field Bus Ports Inside the FCU box there are two terminals X10 and X11 which are used for RS 232C Group Bus communication see Figure 4 14
99. ted deviation can be viewed in holding registers 307 310 4 57 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 4 3 4 Suppressing error indication 4 3 5 4 58 when associated RTG is not present Normally a DAU receives queries from the bus master FCU and picks up level data from the associated RTG However there may be situations when a DAU is installed without bus master and or RTG In this case error codes indicating external serial communication error will be shown on the DAU display These error codes can be suppressed by setting DAU holding register 313 to the appropriate value Database value Action 0 Normal operation 1 No bus master present 2 No associated RTG 3 No associated bus master or RTG DAU Reset The DAU can be reset by switching power off and on with an external switch Another way is to open the box and remove connector X20 on the DMB When replacing the connector the power LED will light up for a short period of time during start up The optional display shows the Unit Id during start up Ind Las Figure 4 29 Connection X20 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 4 3 6 Chapter 4 Service Write Protection There is a write protection switch to prevent unauthorized changes in the EEPROM The switch can be sealed in the write inhibit position using a wire through the clevis pins
100. the EEPROM To download new Transmitter Software 1 Select the Devices folder in the Workspace window or a single device in the Devices folder 2 From the Service menu choose Devices Program All or click the right mouse button and choose the Devices Program All option For single devices choose the Program option Device Iypes REx y REX Available Devices Program these Devices A is A LT 4 a 1 O Moyea Remove e lt lt Remove ll n File Name and Program Version Advanced JE TankMaste REXIBlacy Browse Retries Tope REX Version 11 APPL E s Result Successfully Programmed Devices Device Programming Failed Start Programming Close Help 3 Select the desired device to be programmed from the Available Devices pane and click the Move button Repeat for all devices to be pro grammed If a single device was selected in the workspace window no devices are available in the Available Devices pane In this case the device appears automatically in the Program these Devices pane Use the Remove button if you want to change the list of devices to be programmed 4 5 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Note 4 6 Click the Browse button and locate the flash program file Use xxxB cry file for Boot Software and xxxA cry file for Application Software Always start by downloading the Boot Software Click the Start Programming button Response the Start Devi
101. to the master on request The database contains information on program version communication protocol values slave configuration memory configuration etc It is divided into one write protected and one unprotected part See Chapter 4 1 7 on how to remove the write protection 3 19 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 2 3 Software 3 20 3 2 4 The FCU software controls the collection of data from the units connected to the Field Bus and handles the distribution of data to the TankMaster PC on the Group Bus The Group Bus Process and the Field Bus Process work as interfaces to the serial communication control SCC The EEPROM switch is used by the program to determine if it is allowed to write to the EEPROM The watch dog has to be gritted at least every tenth second or else a reset is performed Direct Memory Access DMA channels in the FCU microprocessor are used to write to the SCC Figure 3 14 Group and Field bus communication When the Group Bus Process receives a query from the master on the Group Bus it will translate the query into the MODBUS format if necessary The query is processed translated back to the original format and the response is sent back to the master The processing of the query could be done in the Field Communication Unit or it could request further processing in the slave units RTGs and DAUs connected to the Field C
102. ts The relay outputs can be configured as Normally Open NO or Normally Closed NC depending on the selected connector on the ROC board There is also a contact used for internal function monitoring Relay2 NO Relay2 NC Relay1 NO iaiia Op CD a O AGA Bottom view of ln Transmitter Head e ose Electronic Unit NO Normally Open Relay Output Card NC Normally Closed Figure 4 12 The relays can be configured as Normally Open or Normally Closed 4 35 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 4 Service August 2010 Normally Open Closed refers to the contact position when a relay is deenergized This is also referred to as the Alarm state The terminology can be summarized as follows Normally Closed Normally Open Alarm reset Alarm reset Normal 4 36 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service Software configuration Relay Outputs 1 Select the desired device icon in the WinSetup workspace window 2 Click the right mouse button choose the Properties option and select the Configuration tab 3 Click the Relay Output button to configure the Relays Response The Rex RTG Relay Output window opens Control Mode Disabled The Arrow Shows the direction the Variable w REX ATG Relay Output 1 LT 1 is ascending from lowest to highest value C Manual Point in absolute value Second Point Point Hysteresis fisoo00
103. ttings Note Some of the electronic cards shown below are optional and may not be installed in your transmitter Signal Processing Card SPC Field Communication Analog Processing Card APC Card FCC Transformer a Transmitter Interface Rectifier Card is AR Card TIC Relay Output Card ROC Figure 3 7 Rex Transmitter Head Electronics 3 7 Service Manual Rosemount Tank Radar Rex 308012En Ed 1 Rev D Chapter 3 Device Description August 2010 3 8 Signal Processing Card SPC The SPC is mainly a digital processor card for advanced signal and communication processing as well as handling of auxiliary functions Analog Processing Card APC The APC is used for filtering and multiplexing of analog input signals By keeping the analog circuitry on a separate card a high Signal to Noise Ratio is achieved Field Communication Card FCC The FCC handles communication with external devices There are different versions of the FCC card allowing you to use various types of communication protocols and even emulate other types of gauges Relay Output Card ROC optional The Relay Output Card ROC contains two relays It allows controlling external devices such as valves pumps heating coils etc Transmitter Interface Card TIC optional The Transmitter Interface Card TIC is required for intrinsically safe auxiliary inputs The TIC includes e Two supply barriers and two input return barrie
104. um level distance 0 0 00 ccc ee eee 3 15 RTG Reference Distance a a ee es 3 14 Tank Reference Height 0 0 0 0 eee eee 3 14 Tank Reference Height seria bode e did dha 5 5 TCOMuntemtace DOardsS wns sd eaten martes rd 3 19 Technical Data ANAlOOINDUS ricos dd eee atte cee eed bee oh Mets 3 11 Analog OPUS dota a AA Ea 3 12 A A 9 7 FBM 2190 cotas deidad ea oa ee 9 9 e A A AN 9 6 Rel OUND US rt rre ao e ONS nos tree ay Sead diran dais dal 3 11 AE OO20 A o OH ROS ee eh ee ek Se a ES 9 2 Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Index RG 6900 wt gas nd bee ete oe Se ee aes eee Owes 9 3 FOO iras cs ea aed cal de a ii cite A eee ws ERE 9 5 Temperature average measurement 0 02 cee ee 4 56 Temperature measurement 00 00 ee ee eee 3 24 4 15 Temperature measuring error 1 ees 4 65 Temperature Multiplexer Card 0 0 0 0 ee eee 3 8 4 15 Temperature references 0 0 ccc ee ee ee ee ees 3 29 Temperature SENSOl evasiva 3 8 3 24 CONTOU UON staba duda tout da ya a 4 20 Temperature spot measurement o o o oo ooooonon ees 4 56 MGFIMC Connguranion lt cs o hee te bet een eee eS Boe eee EE ea ee 4 16 THIMCOULSCUINGS 3 tiie tic e ae ek Ree eee id ee 4 66 TMC ONG osmana tira darla dete an Gest rl Ata eA at dah dp festa Be teeta ob acaba 4 16 TOJE FENO eset teed ates Riva tees atte eee eed eeees 4 38 TanSMItler CAG wick aaa eed BBR we ee SOS
105. unication is established 5 Click the OK button to continue 14 Select the Configuration tab and choose the Redundant Backup mode option to set the operation mode 15 Check that holding register 831 7 16 Power down the FCU 17 Move switch X14 to position 1 on both FCUs Position 1 4 52 18 19 Power up the primary FCU first and then the backup FCU Comment Now the primary FCU which was powered up first becomes active Check that TankMaster reads data from the active FCU Select the FCU icon click the right mouse button and choose the Properties option and check that the Unit ID corresponds to the active FCU Service Manual 308012En Ed 1 Rev D Rosemount Tank Radar Rex August 2010 Chapter 4 Service 20 Check the diagnostics Input Register Input Register 30689 to verify that the primary FCU is active This is indicated by status bit 12 0 If the backup FCU is active status bit 12 1 21 Power down the active FCU Comment The backup FCU switches from inactive to active 22 Make sure that the backup FCU is active This is indicated by status bit 12 1 see step 20 23 Power down both FCUs and then power up the FCUs again starting with the primary FCU as described in step 18 24 Select the FCU Slave Database tab from the Properties menu and con figure the FCU pair like you would configure a single non redundant FCU Both FCUs will receive the same data Switch between the FCUs to make sure that the sa
106. vice Manual 308012En Ed 1 Rev D August 2010 RTG 0 5 mm 5 256 in RTG 3950 L 3 mm 1 8 in 40 C to 120 C 40 F to 248 F 0 8 to 40 m 2 6 to 130 ft from antenna end Fixed version 0 2 to 2 bar 2 9 to 29 psig at 20 C Inclined version 5 to 8 in pipes 0 2 to 0 5 bar 2 9 to 7 2 psig 10 and 12 in pipes 0 2 to 0 25 bar 2 9 to 3 6 psig Antenna Polyphenylensulfid PPS sealing PTFE O ring Fluorosilicone Flange Acid Proof Steel EN 1 4404 AISI 316L 21 5 32 kg for fixed version and 28 5 41 5 kg for inclined version depending on dimension 5 6 8 10 or 12 in Service Manual 308012En Ed 1 Rev D August 2010 9 5 RIG 3960 Instrument accuracy Operating temperature at ball valve Operating temperature in tank Ambient temperature Measuring range Maximum pressure Pressure sensor option Material exposed to tank atmosphere Total weight Still pipe dimensions Rosemount Tank Radar Rex Chapter 9 Technical Data RTG 3900 0 5mm 5 256 in RTG 3900L 3 mm 1 8 in 55 C to 90 C 67 F to 194 F 170 C to 90 C 274 F to 194 F 40 C to 70 C 40 F to 158 F 0 5 m to 60 m 1 6 ft to 200 ft from cone end Up to 25 bar 365 psig Druck PTX 621 Antenna Acid proof steel type EN 1 4436 AISI 316 Sealing Quartz 6 in 150 lIbs appr 38 kg 84 Ibs 6 in 300 Ibs appr 48 kg 106 Ibs 4 in Sch 10 or 100 mm inner dia

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