Thermo MeasureTech 1440 Microwave Level Gauge User Manual AccuWave Installation Manual

Thermo MeasureTech Microwave Level Gauge AccuWave Installation Manual

Contents

Installation Manual

Accu-Wave Radar Gauge Radar-Based Continuous Level Measurement Installation Manual DRAFT Part No. 717790
Accu-Wave Radar Gauge Radar-Based Continuous Level Measurement Installation Manual DRAFT Part No. 717790 Version 1.0 March 2000
Disclaimer TN Technologies has made every effort to ensure the accuracy and completeness of this manual. However, we cannot be responsible for errors, omissions or any loss of data as a result of errors or omissions. TN Technologies reserves the right to make changes to the manual or improvements to the product at any time without notice. The material in this manual is proprietary and cannot be reproduced in any form without express written consent from TN Technologies. Refer to the equipment tag shipped with your gauge to verify the certifications for hazardous location use applicable to your gauge. Refer to the Installation Manual and the Installation/Wiring Drawings for installation instructions. Trademarks All registered trademarks are the property of their respective companies. © 2000 TN Technologies TN Technologies 2555 North Interstate 35 P. O. Box 800 Round Rock, Texas 78680-0800 TN Technologies also offers a complete line of portable x-ray fluorescence analyzers.
Accu-Wave Table of Contents i TN Technologies Table of Contents Chapter 1 Introduction ................................................................................................................................ 1-1 Description ..................................................................................................................................................... 1-1 Features and Benefits ...................................................................................................................................... 1-3 How the Accu-Wave Works............................................................................................................................ 1-4 How to Use This Manual................................................................................................................................. 1-5 TN Technologies’ Service Department ............................................................................................................ 1-5 Chapter 2 Hardware Installation................................................................................................................. 2-1 Licensing........................................................................................................................................................ 2-1 Hazardous Location Approvals........................................................................................................................ 2-2 Selecting a Location........................................................................................................................................ 2-2 Mounting the Gauge........................................................................................................................................ 2-4 Chapter 3 Wiring Procedures...................................................................................................................... 3-1 Initial Wiring Preparations .............................................................................................................................. 3-1 Wiring Instructions ......................................................................................................................................... 3-2 Appendix A How to Return Equipment for Service ...................................................................................... A-1 Appendix B Parts List.................................................................................................................................... B-1 Appendix C Specifications.............................................................................................................................. C-1 Appendix D Installation Drawings................................................................................................................. D-1
Accu-Wave Chapter 1 Introduction TN Technologies 1-1 Chapter 1 Introduction The Accu-Wave Model 1440 Radar Level Gauge uses a microwave signal to continuously measure the level of the process material. The Accu-Wave provides better performance than sonic measurement systems, particularly in hostile environments, because the microwave signal is unaffected by mist, surface agitation, temperature changes, or pressure changes. The standard menu-driven user interface, with built–in help screens, the optional Windows-based Setup Software are designed to make the gauge easy to set up and operate. The Accu-Wave transmits a microwave signal that is reflected from the surface of the process material. The reflected signal or echo is received by the Accu-Wave. The Digital Signal Processing (DSP) software detects the echo and computes the distance to the liquid or solid material in the tank. The Accu-Wave firmware uses the distance measurement to calculate level, volume, and other user-selected measurements. Description The Accu-Wave Radar Level gauge consists of an integrated sensor and transmitter with the microwave sensor and transmitter circuitry combined on a single electronics board. The microwave signal is launched from the bottom of the board via a cup/probe assembly into the antenna. The antenna serves to focus the transmitted signal as well as to receive the reflected echo. Currently, the Accu-Wave is available with dielectric rod antennas. Horn antennas will be available as a future option. Antennas The standard antenna configuration for the Accu-Wave gauge consists of a dielectric-filled, 1 inch O.D. stainless steel waveguide with a dielectric rod antenna. The dielectric rod antenna is available in either polypropylene or Teflon (PTFE). The stainless steel (SS 316) waveguide material is swaged (crimped) over the dielectric-fill material. The swage serves both as a process seal as well as a pressure seal. The PTFE antenna design also uses O-rings to ensure the integrity of the process seal. Viton and Kalrez O-rings are available. Horn antennas, with diameters ranging from 2 to 8 in., will be available as a future option. Mounting Configurations The dielectric rod antennas are fitted with either a 1-inch NPT threaded bushing, welded to the waveguide, or with a welded flange. The available flanges sizes are 150 lb. or 300 lb., with diameters of 2, 3, 4, or 6 inches. Waveguides are provided in lengths of 6, 9, 12, or 15 inches lengths, where the length refers to the portion of the waveguide that extends below the bushing or the flange. For optimum performance, the end of the waveguide should extend to the bottom of the tank nozzle or below. Level measurements can be made even when the process material level is in contact with the dielectric antenna to within ~3.5 inches of the bottom of the steel waveguide.
Chapter 1 Introduction Accu-Wave 1-2 TN Technologies Measurement accuracy, however, is degraded when the process level is above the bottom of the probe. Approvals The Accu-Wave is certified for use in hazardous locations as follows (approvals are pending as of 1 March 2000): FM • Class I, II, III, Division 1, Groups B, C, D, E, F, G • Class I, II, III, Division 2, Groups B, C, D, F, G • NEMA 4X CSA • Class I, II, III, Division 1, Groups B, C, D, E, F, G • Class I, II, III, Division 2, Groups B, C, D, E, F, G • TYPE 4X CENELEC • EEx d IIB + H2 • Eex n IIB + H2 See Appendix C for additional information regarding specifications and safety approvals. Note: Verification of chemical compatibility with the exposed antenna materials is ultimately the responsibility of the customer. Sensor-Transmitter The sensor and transmitter are integrated on a single electronics board. The transmitter detects the signal reflected from the process material, determines the distance to the surface of the process material, and calculates other measurement values. These values can be displayed on a local/remote display, sent to the serial ports (RS-485 standard, RS-232 optional), and can be used to drive the 4-20 mA current output or process alarms. The RS-485 and optional RS-232 serial ports support communications from a PC with the Accu-Wave Window’s based Setup Software, a PC with terminal emulation software, or a TN Technologies' Hand Held Terminal. The Accu-Wave supports 4-20 mA current output, serial communications, a contact closure input, and a 2-line local/remote display. The Accu-Wave inputs and outputs are summarized in the following Input/Output Characteristics Table.
Accu-Wave Chapter 1 Introduction TN Technologies 1-3 Input/Output Characteristics Type Characteristics Comments Current output 0-20 mA dc (adjustable range) Isolated, Loop-Powered, 24 Vdc Nominal Supply Voltage, 700 ohm max. load Default range is 4-20 mA dc. One current output is provided. Serial communications RS485: One terminal block and one RJ11 Jack RS 232: One terminal block (Requires optional board.) Half-duplex party line communication to host computer or Hand-Held Terminal. Full duplex communication with a remote terminal or PC. Contact closure input One (1) contact closure input is provided. The user can assign a command to execute based on user-provided contact opening or closure input to the gauge. Remote Display 2 Line x 16 Character Display - Backlit Features and Benefits Dynamic Menu System You see only the menu options pertinent to your application. The initial “Set up level, ...” menu takes you through a basic setup to get your instrument up and running quickly. Help screens are available at appropriate points. Built-in Volume Measurement Select one of the pre-defined tank shapes, enter its dimensions, and the gauge computes volume from an internal equation library. Alternately, you can define volume as a polynomial expression based on the level (height) or as a break table of volume and height value pairs. Instantaneous Response TN Technologies Dynamic Process TrackingTM (DPT) ensures no lag time in the system response to level changes. When sudden process changes occur, the DPT feature reduces the normal averaging time constant by a factor of eight, ensuring a smooth and rapid output response. When the process stabilizes, the longer time constant is applied to reduce spurious fluctuations in the measurement. In this way, actual changes in process level are immediately reflected in the transmitter output, while the effects of signal variations from turbulence and other short term factors on the measurement are greatly reduced.
Chapter 1 Introduction Accu-Wave 1-4 TN Technologies Extensive Alarms You can set up as many as 16 process alarms in addition to system fault alarms and warning alarms. Quick and Easy Setup The menus take you through the setup procedure step–by–step. Built-in help screens are provided at appropriate points in the menu structure. Multiple Readouts You can select up to six of the following values for display: level, distance, volume, unfilled volume, percent full, percent empty, percent distance, percent level, signal strength, or alarm relay status. The screen automatically displays the measurement values three at a time in alternation. The measurement values can also be sent to a remote terminal or a computer. Marker Sweep Software TN Technologies’ patented Marker Sweep software continually adjusts the transmitter output signal to maintain linearity. This highly consistent microwave signal ensures reliable, stable system operation and accurate level measurements. Digital Signal Processing (DSP) The gauge uses DSP hardware and software to process the received microwave signal (the echo) and to provide accurate, real-time measurements of the distance to the surface of the process material. How the Accu-Wave Works The sensor generates a microwave signal composed of electromagnetic waves – two perpendicular oscillating fields (electric and magnetic) that travel together. The transmitted signal is reflected from the surface of the process material. This echo is detected and evaluated for changes in frequency to determine the distance to the liquid or solid material in the tank. The Marker Sweep software continually adjusts the signal output to maintain the linearity of the transmitted frequency sweep. This highly consistent microwave signal ensures that changes in level are reported accurately in real-time. Dynamic Process Tracking software ensures quick system response to changing process levels by automatically reducing the response time when level changes occur. A variety of tools are provided in the menus to “fine tune” the signal in order to eliminate many of the problems associated with measuring levels in an active process. TN’s exclusive DSP software processes the microwave signal and converts it to measurement information displayed in the readout. You can also program measurements to drive alarms, or open and close switches. The alarms, user inputs, and selected outputs are saved in non-volatile memory.
Accu-Wave Chapter 1 Introduction TN Technologies 1-5 Automatic verification and error correction software continuously monitors system operations. System faults can be programmed to set off alarms. How to Use This Manual This manual provides installation and maintenance/troubleshooting procedures for the Accu-Wave gauge. Installation and Maintenance Note: Reduced-size copies of the drawings referenced in this manual are included in . Chapter 2, “Hardware Installation,” provides instructions for mounting the Accu-Wave sensor and transmitter. Chapter 3, “Wiring Procedures,” describes how to wire the power source to the gauge and other wiring, such as the current output and serial communications. Additional Information Appendix A, “How to Return Equipment for Service,” gives you shipping information for returning equipment to TN Technologies for service. Appendix B, “Parts List,” lists the parts of the Accu-Wave. Refer to this list if you need to order parts. Appendix C, “Specifications,” contains the specifications for the Accu-Wave. Appendix D, “Installation Drawings,” contains reduced-size copies of the drawings referenced in this manual. Setting Up and Using the Gauge The companion manual “Accu-Wave Operation Manual” (717791) provides detailed information on how to set up the Accu-Wave software and operate the Accu-Wave gauge. TN Technologies’ Service Department The TN Technical Services Department is available to help you with any problems you may have installing or operating your gauge. Call us with your questions or comments: • Phone: (800) 736–0801 (US only) • Main Office: (512) 388–9100 • FAX: (512) 388-9200
Accu-Wave Chapter 2 Hardware Installation TN Technologies 2-1 Chapter 2 Hardware Installation Licensing All microwave frequency tuning is completed at the factory (TN Technologies Inc., Round Rock, Texas). United States For installations on metal tanks, the Accu-Wave complies with FCC Part 15 requirements, FCC ID MCO1440-15, and no additional licensing is required (Part 15 certification is pending) Note: Operation under Part 15 of the FCC Rules is subject to the two following conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. For installations other than on metal tanks, you must obtain and display a FCC Part 90 license at the installation site, FCC ID MCO1440 (Part 90 certification is pending). TN Technologies can assist you with licensing. For assistance, call or fax one of the following numbers: • Phone: (800) 736-0801 (US only) • Main Office: (512) 388-9100 • FAX: (512) 388-9200 Canada (i) This device shall be installed and operated in a completely enclosed metal container to prevent RF emission which otherwise can interfere with aeronautical navigation. Installation shall be done by trained installers, in strict compliance with the manufacturer’s instructions. (ii) The user of this device is on a “no-protection non-interference” basis. That is, the user shall accept Government and NAV CANADA operations of high powered radar in the same frequency band which may interfere with this device. Devices found to interfere with Government and NAV CANADA operations will be required to be removed. (iii) The user is required to notify the TN Technologies at 2555 N. IH 35, Round Rock, TX, 78680 of the postal address of the user, the address where the device is installed, the device model number, and the date of installation.
Chapter 2 Hardware Installation Accu-Wave 2-2 TN Technologies Hazardous Location Approvals The Accu-Wave is certified for use in hazardous locations as follows (approvals are pending as of 1 March 2000): FM • Class I, II, III, Division 1, Groups B, C, D, E, F, G • Class I, II, III, Division 2, Groups B, C, D, F, G • NEMA 4X CSA • Class I, II, III, Division 1, Groups B, C, D, E, F, G • Class I, II, III, Division 2, Groups B, C, D, E, F, G • TYPE 4X CENELEC • EEx d IIB + H2 • Eex n IIB + H2 Warning: Do not locate the unit in any hazardous area other than those approved. Follow all instructions on the installation drawings. Do not apply power to the unit in any hazardous area unless the safety ground is properly wired inside the unit and the cover is properly installed. See Chapter 3 for installation wiring instructions. Hazardous Location Installations: The cable entries must be sealed per the Installation Layout Drawing (868502). Non-Hazardous Location Installations: The cable entries into the enclosure must be sealed with a compound to protect against the passage of gas or vapors. The sealing compound should not be affected by the surrounding atmosphere or liquids. The minimum thickness of the sealing compound should be 5/8 in (16 mm). Selecting a Location Selecting a good location to mount the transmitter can ensure the accuracy and ease of operation of your gauge. Guidelines Follow these guidelines when selecting a location for the Accu-Wave gauge: 1. The operating temperature range is –40ΟC to 70ΟC (–40ΟF to 158ΟF). 2. The sensor should be mounted above the smoothest portion of the process material surface.
Accu-Wave Chapter 2 Hardware Installation TN Technologies 2-3 3. There should be a clear path between the sensor and process material to avoid false reflections. Verify that the path is clear of pipes, beams, or any intermittent liquid sprays that could block the microwave beam. Also try to locate the sensor to keep the beam path (approximately 18º wide) clear of the following: − Turbulence, splashing, or waves such as those caused by filling, recirculation, or sparging of light material entrances near the bottom of the tank. − Pipe entrances near the top or side of the tank. − Agitator blade passing directly through the beam path. If this can not be avoided, use the “agitator reject time” feature on the “Radar fine tuning” menu, discussed in the Accu-Wave Operation Manual (717791). − Vortices caused by baffles, drains, or any other obstructions. 4. The mounting location should also avoid horizontal structural surfaces such as baffle support brackets, side wall joints, and so forth, because these surfaces reflect a strong false signal. If this cannot be avoided, refer to the section “False Echo Management” in Chapter 5 of the Operation Manual (717791). 5. If the vessel has a dome top, a good guideline is to mount the sensor away from the vessel’s center point by at least 10% of the vessel diameter. Note: If the sensor is mounted in the center of the vessel, the dome top will act as a parabolic antenna, potentially enhancing “false” echoes due to multiple reflections of the transmitted energy. The tank’s nozzle must meet the following requirements. 1. Rod antennas: the internal diameter of the nozzle must be larger than 1 inch. For best performance, the bottom of the stainless steel waveguide tube must be even with the bottom of the nozzle or extend below the bottom of the nozzle. 2. Intrusive horn antennas: the internal diameter must exceed the horn diameter (3, 4, 6, or 8 inches). The nozzle must be free of burrs and other obstructions. 3. Process isolation horn antennas: The internal diameter of the nozzle section needs to be the same along the length of the nozzle. The nozzle must be free of weld beads, steps, burrs, or abrupt changes in nozzle diameter. 4. Nozzle must meet or exceed tank pressure requirements. 5. Align nozzle within 3º of vertical (verify this with a carpenter’s combination level). Flange surface must be aligned within 3º of horizontal (verify this with a carpenter’s combination level). Dimensional Drawings Refer to the appropriate drawings for the sensor mounting dimensions: • Rod Antennas – refer to drawing 868656. • Horn Antennas – refer to drawing TBD (future option). Reduced-size copies of the drawings are provided in Appendix D.
Chapter 2 Hardware Installation Accu-Wave 2-4 TN Technologies Mounting the Gauge When mounting the gauge, ensure there are no obstructions between the antenna and the surface of the process material. If obstructions cannot be avoided, refer to “False Echo Management” in the Accu-Wave Operation Manual (717791). Caution: Use proper lifting procedures to avoid injury. Rod Antenna 1 Inch NPT Bushing Mounting To mount a gauge with the 1 inch NPT bushing mounting option, simply screw the threaded bushing into the corresponding fitting on the tank. Note: Do not apply force to the housing to tighten the bushing. Use a wrench on the hexagonal portion (1 3/8 in.) of the bushing. Mount the gauge to the tank before attaching any wires or conduits. Flange Mounting Instructions You need the following (supplied by the customer): 1. 1 gasket suitable for the process material 2. 16 steel washers 3. 8 nuts and bolts 150 lb flange – use 5/8 inch hardware 300 lb flange – use 3/4 inch hardware Refer to dimensional drawing 868656. Follow these steps to mount the gauge. 1. Center the gasket, suitable for your process material, on the nozzle flange. 2. Slide the antenna into the opening. Center the sensor flange on the gasket and line up the bolt holes in the sensor flange and the nozzle flange. 3. Install the bolts and washers, and attach the nuts. Tighten the bolts in a star-patterned sequence to equalize compression.
Accu-Wave Chapter 3 Wiring Procedures TN Technologies 3-1 Chapter 3 Wiring Procedures The Accu-Wave electronics includes the following boards. • Main Electronics Board • RS-232 daughter board (optional). • Hart Communications daughter board (future option). The required wiring steps are: • connect 24 Vdc power supply to the gauge, and • connect a remote computer terminal or Hand Held Terminal to the gauge via the serial communication port. Additional, optional wiring may include: • 4-20 mA current output, • contact closure input, or • optional, remote display (2 line x 16 characters). Caution: Remove all power from the unit before making any connections. WARNING: All wiring must be done by qualified individuals in accordance with applicable codes such as the NEC (National Electric Code) ANSI/NFPA 70 specifications or the Canadian Electrical Code Part 1. Initial Wiring Preparations Warning: Do not apply power to the unit in any hazardous area unless the safety ground is properly wired inside the unit and the cover is properly installed. Hazardous Location Installations – The cable entries must be sealed per the Installation Layout Drawing (868502). Non-Hazardous Location Installations – The cable entries into the enclosures must be sealed to prevent passage of gas or vapors. The sealing compound should not be affected by the surrounding atmosphere or liquids. The minimum thickness of the sealing compound should be 5/8 in (16 mm). If metal conduit is used, the conduit must be grounded. Caution: Insulate the drain wire to eliminate ground loops. Caution: CSA certified fittings must be used to maintain CSA rating for enclosure.
Chapter 3 Wiring Procedures Accu-Wave 3-2 TN Technologies Wiring Instructions You will need a 1/8 inch bladed screwdriver to connect the wires to the plug-in connector. Refer to the Installation Layout drawing 868637 and Wiring diagram 868641. Follow all notes on the drawings. To wire the gauge: 1. Loosen the retaining screw at the base of the enclosure lid, then unscrew and remove the enclosure lid. 2. Pull the cable(s) through the conduit opening(s) in the enclosure. 3. Connect the power cable ground to the internal ground on the bracket (the bracket is grounded to the enclosure. 4. Remove the plug-in screw-terminal connector from the board. Loosen the terminal screws. Insert the wires and make connections as shown in the appropriate installation wiring diagram. Tighten the screws in the plug-in connector to secure the wires. Replace the connector on the board when all wires are secured. 5. Screw the enclosure lid back onto the housing and tighten the retaining screw. DC Power Wiring The Accu-Wave is designed to operate on 24 Vdc ± 25%. The maximum input power requirement is 12 W. As shown in this wiring diagram (868641), to connect DC power to the main board: 1. Connect +24 Vdc to Pin 1 of the J1 connector, and 2. Connect the return for the +24 Vdc supply to Pin 2 of the J1 connector. Note: To meet the requirements of CSA 1010.1, the input DC terminals shall be supplied from an SELV (Safety Extra Low Voltage) source. In addition, protective bonding (grounding) must always be provided. 4-20 mA Current Output The current output range is programmable (refer to the Accu-Wave Operation Manual). The maximum range is 0.4 to 20 mA and the default range is 4 to 20 mA. Isolated, loop-powered, nominal voltage requirement is 24 Vdc for a 700 Ω load. As indicated in the Wiring Diagram (868641), connect the +24 Vdc input to Pin 7 of the J1 connector on the main board. Contact Closure Input The contact switch input is dry contact input between ground and switch closed position.
Accu-Wave Chapter 3 Wiring Procedures TN Technologies 3-3 Serial Communications The gauge provides an RS-485 multi–drop serial interface port. An RS-232 single–drop is available with the optional RS-232 daughter board Both ports provide independent access to the measurements and software functions. The ports can be used simultaneously. The RS-485 port can communicate with a PC running the Accu-Wave Setup Software, a PC running a terminal emulation program, TN Technologies’ Hand-Held Terminal, ANSI terminals, or VT100 terminals. The RS-232 port can connect directly to a PC serial (COM) port using a serial cable. Note: In order to communicate with a PC via the RS-485 port, an RS-485 to RS-232 converter (TN part No. 885960) is required.
Accu-Wave Appendix A Returning Equipment for Service TN Technologies A-1 Appendix A How to Return Equipment for Service Call the TN Technical Services Department (Factory Service division) before returning equipment for repair. Many problems can be diagnosed and resolved over the phone. For after hours or weekend service, call our 24-hour Service number: 512-388-9320. Please include the following information with all units returned for repair: 1. Specific information about the problem. 2. A point-of-contact name and phone number, in case we need more information. 3. A purchase order authorizing repairs, or a request for a quote. 4. Ship prepaid to the address below: Factory Service Department TN Technologies 2555 North IH 35 Round Rock, Texas 78664 The Receiving Department will not accept collect shipments. Do not ship to our P. O. Box.
Accu-Wave Appendix B Parts List TN Technologies B-1 Appendix B Parts List Part No. Description 886639 Main Electronics Board 886641 RS-232 Daughter Board (option) Windows Set-up Software (CDROM) 717790 Installation Manual 717791 Operation Manual 885960 RS-485 to RS-232 converter
Accu-Wave Appendix C Specifications TN Technologies C-1 Appendix C Specifications Operating Principle Frequency modulated continuous wave (FMCW) radar signal which measures distance; microprocessor based transmitter computes level, volume and nine other measurements. Range Up to 115 ft. (35 m.) Reference Accuracy ±3 mm (1/8 in.) Repeatability ±3 mm (1/8 in.) Input Power 24 Vdc ±25%, 12 W Serial Outputs & Inputs RS-485 (Standard): Half duplex partyline communication to a host computer or hand-held terminal. RS-232 (Optional): Full duplex communication with a remote terminal, printer, PC or host computer. Current Output 4 to 20 mA, isolated, loop-powered (24 Vdc). Maximum load – 700 ohms. Compliant with NAMUR 43 specification for fault current. Contact Closure Input 1 contact closure input provided. (User provides switch.) Circuit Protection Meets IEC 801-1,-2, and –3 Current output is isolated. Microwave Emissions In compliance with ANSI C95.1, “RF Field Exposure Safety Guidelines” Dimensions Refer to Dimensional Drawings Rod Antenna: D868217 Horn Antenna: TBD Weight Rod Antenna: ~15 lbs. Horn Antenna: TBD. Temperature Range (Electronics) -40o C to +70oC (-40o F to +158o F) Pressure Rod Antenna PP 600 psig. max. PTFE 300 psig. max. Exposed Materials (Process) Rod Antenna SS316 and Polypropylene, or SS316, PTFE, and O-ring material. Horn Antenna TBD Mounting Rod Antenna 1 inch NPT bushing, or Welded flange (150/300 lb.; 2, 3, 4, 6 inch ) Horn Antenna TBD Hazardous Location Approvals FM Class I, II, III, Division 1, Groups B, C, D, E, F, G Class I, II, III, Division 2, Groups B, C, D, F, G NEMA 4X CSA Class I, II, III, Division 1, Groups B, C, D, E, F, G Class I, II, III, Division 2, Groups B, C, D, E, F, G TYPE 4X CENELEC EEx d IIB + H2 Eex n IIB + H2
Accu-Wave Appendix D Drawings TN Technologies D-1 Appendix D Installation Drawings This Appendix contains reduced size copies of the drawings referenced in this manual. The drawings are provided in the order listed below.

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