Manual Tankradar Rex Commissioning Manual Rosemount en 80812

Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
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Commissioning manual
Second edition
Revision B
Copyright © June 2008

Rosemount Tank Radar AB
Copyright © June 2008
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 registered trademarks of
Rosemount Inc.
TankRadar is a registered trademark of Rosemount Tank Radar AB.
HART is a registered trademark of HART Communication Foundation
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 FCC 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.
308011En, Ed.2/Rev.B Rosemount TankRadar Rex
June 2008 Table of Contents
Contents
1. CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 TANK INTERIOR CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 SYSTEM COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 FCU CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5.1 FCU information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5.3 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.4 Field bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.5 Group bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 FBM 2180 CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.6.1 FBM information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6.3 Field bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 COMMUNICATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.8 RTG 3900 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.8.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.8.2 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8.3 Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.9 RTG 3920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.9.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.9.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.9.3 Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.9.4 Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.10 RTG 3930 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.10.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.10.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.10.3 Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.10.4 Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . 1-11
TOC-1
Rosemount TankRadar Rex 308011En, Ed.2/Rev.B
Table of Contents June 2008
1.11 RTG 3950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.11.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.11.3 Still-Pipe Requirements . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1.11.4 Free space requirements . . . . . . . . . . . . . . . . . . . . . . . .1-13
1.12 RTG 3960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.12.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1.12.3 Still-Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1.12.4 Verification Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.13 REX CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

1.13.2 Tank Distances and RTG Geometry . . . . . . . . . . . . . . . .1-19
1.13.3 Rex configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
1.13.4 Input Register parameters . . . . . . . . . . . . . . . . . . . . . . .1-21
1.13.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
1.14 DATA ACQUISITION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

1.14.2 Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
1.14.3 Cable and Junction box . . . . . . . . . . . . . . . . . . . . . . . . .1-23
1.14.4 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14.5 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
1.14.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.15 DAU CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

1.15.2 Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.15.3 Current inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.15.4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.16 OPERATOR SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

1.16.1 TankMaster WinOpi . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
1.16.2 Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-1
TOC-2
June 2008 Chapter 1 Checks and Adjustments
1. Checks and Adjustments
1.1 General
Commissioning a Rex system aims at checking the mechanical and

electrical installations.
It includes calibrations and adjustments in order to achieve high

accuracy and reliability. The communication between various TRL/2 and
Rex units is checked, and necessary backups of database files etc. are
created. It also includes checking that the installations are done
according to safety regulations.
This manual provides brief descriptions of most of the items in the Check
List for Rosemount TankRadar Rex. The checklist is used as a guide
when commissioning a Rex system. When you need more information
on a certain item in the check list, read the corresponding section in this
chapter for further information.
Note! Before commissioning a Rex system, always read the Rex Installation
Manual (Document No. 308014), Rex Special Safety Instruction
(Document No. 308016), and Rex Safety Manual (SIL2; Document No.
308020).
1.2 Preparations
Check that the equipment is undamaged and that it corresponds to the

specifications. Note the following information:
• Delivery no. the system number provided by the project depart-

ment at Emerson Process Management/Rosemount Tank
Gauging.
• Name and location of plant.
• Service agency: the name of the local agency responsible for the
installation.
• Engineer responsible for the commissioning, and the date when

commissioning was concluded.
• Note the tank distances needed for installation and configuration

of the Rosemount Tank Radar Rex system. See “Tank measure-
ments” on page 1-8 for illustrations of the different tank distances.
• Note the addresses to be used for the communication between the

connected devices (RTG, DAU, FCU) and TankMaster.
1-1
Chapter 1 Checks and Adjustments June 2008
• Check that the correct hardware parts are installed.
• Make sure that you bring appropriate tools and instruments.
• Install TankMaster.
1.3 Tank Interior Conditions
Look for objects which may produce disturbing echoes like girders,
heating coils or agitators. Disturbing objects can severely affect the
accuracy of the measurements.
1.4 System Composition
Enter the following information about the system:
• Number of tanks.
• System Master. There may be several units acting as master at

different occasions. The system is supervised by TankMaster
(WinOpi). A portable service PC may temporarily be connected to
an FCU when system service is required (WinSetup). A host com-
puter can be connected to an FCU or to the TankMaster PC in
order to further process measured data (level, temperature, pres-
sure etc.).
• The number of FCUs, FBMs, RTGs and DAUs.
1.5 FCU checklist
1.5.1 FCU information
Note the name, Unit ID

and address of each FCU.
This will facilitate the
configuration of the Rex
system. Check that the
Unit ID placed at the cover
of the FCU box and on the
FCU motherboard match.
Note the address which
will be used for the
different FCUs. Figure 1-1. Position of Unit ID on FCU
cover.
1.5.2 Visual check
• The FCU is not intrinsically safe. It must therefore be installed in a

nonhazardous area.
• Weather protection: make a note whether the FCU is placed in a

control room or another weather protected location.
1-2
1.5.3 Electrical check
• Power supply. Check that the switch inside the FCU box is set to
the correct value. 230 V is the default value. If 115 V is used, the
box on the nameplate "Mark box if re-wired for 115 VAC" shall be
marked.
• Grounding: if there is no protective ground in the mains supply

cable, the FCU should be externally grounded via the ground con-
nection at the outside of the FCU box.
1.5.4 Field bus check
• Use a shielded twisted pair cable with an area of at least 0.50 mm2
for the TRL/2 bus.
• Shielded cables are required in order to avoid crosstalk if the

cables run alongside and also to avoid other disturbances. The
field bus shield should be connected to ground at the FCU only.
Contact Emerson Process Management/Rosemount Tank
Gauging for further instructions.
• Note the distance if there are two fieldbuses running in parallel.
1.5.5 Group bus check
• Note the number of group buses that are used. The FCU can be
configured with two, three or four group bus ports.
• Note whether the group bus communicates via the RS-232C or

the TRL/2 bus interface. By replacing the FCM board with an FCI
board, RS-485 communication can also be used.
1.5.6 Software
• Note if redundant FCUs are used.
• Note the FCU program version.
To view the FCU program version:
1 Select the FCU icon in the TankMaster WinSetup workspace.
2 Click the right mouse button and choose the Properties option.
3 Select the Communication tab.
1-3
1.6 FBM 2180 checklist
1.6.1 FBM information
• Note the name and version of each FBM.
1.6.2 Visual check
• Note if the FBM is installed outdoors or in the control room.
• Check if there is anything in the surroundings which may disturb

the communication such as electromagnetic fields like radiators,
big motors and transformers.
1.6.3 Field bus check
• Check that the TRL/2 bus is connected to socket 2 and 3. Use

twisted and shielded single pair cable with minimum cross sec-
tional area 0.50 mm2.
Cable dimension Maximum length
AWG 20 (0.50 mm2) 3000 m
AWG 18 (0.75 mm2) 4000 m
Table 1-1: Recommended wiring length
• Connect the shield to terminal 1 or 4.
• Connect ground cable to terminal 1 or 4.
TRL/2 bus
Figure 1-2 FBM 2180
1.6.4 Power supply
• Do not use external power supply when the modem is connected

to the USB port. The USB interface itself supports power to the
FBM 2180 modem.
1-4
1.7 Communication overview
Make a simple drawing showing all tanks and installed units, see Figure
1-3. Include cable lengths. Describe the composition of tanks, Radar
Tank Gauges, Data Acquisition Units, Field Communication Units, Field
Bus Modems and system master. Try to provide as much detail as
possible. A complete view of the system including TankMaster WinOpi
and host computers should be provided, including information on which
Rex units the host computer is connected to.
TankMaster
WinOpi
Plant host
computer
FBM
Group Bus
(TRL/2 Bus)
Portable
Service PC
FCU FCU
Field bus
RTG/ RTG/ RTG/

DAU DAU DAU
Tank 1 Tank 2 Tank 3

Tank Group 1
Field bus
RTG/ RTG/ RTG/

DAU DAU DAU
Tank 4 Tank 5 Tank 6
Tank Group 2
Figure 1-3 Example of System Composition drawing.
1-5
1.8 RTG 3900 - General information
1.8.1 Tank Information
• Tank name
• Product in tank
• Note the Unit ID, see Figure 1-4 It can also be found on the Signal
Processing Card (after C on the label). See TankRadar Rex Instal-
lation Manual Ed. 3 rev.B, chapter 3.1.1 for information on the
Transmitter Head Electronics Card.
Figure 1-4 Label with Unit ID.
• RTG Power Supply: The 3900 Rex transmitter accepts 100-240

VAC, 50-60 Hz and max. 80 W. The built-in Transformer Rectifier
Card (TRC) automatically adapts to the connected supply voltage.
Optional: low voltage AC/DC versions (34-70 VAC/48-99 VDC).
• Grounding: Certain national regulations requires protective

grounding of enclosure, see Special Safety Instruction for further
information. Special Safety Instruction is delivered together with
each Rex transmitter. Check with Emerson Process Management/
Rosemount Tank Gauging and/or local authorities if necessary.
• Field bus continuity: Measure the resistance between leads 3

and 4. Resistance values between 1 and 20 Ω indicate that the
field bus cable is undamaged and correctly connected.
• Field bus shield grounding: Check that the field bus shield is
connected to ground at the FCU only, and not at the RTG.
1-6
1.8.3 Tank measurements
• Tank reference distance, R. The R distance is defined as the dis-

tance between the dipping datum point (zero level) and the tank
reference point.
• RTG reference distance, G. G is the distance between the tank

reference point (hand dip nozzle) and the RTG reference point.
The RTG reference point is underneath the RTG flange, see Fig-
ure 1-5.
• Minimum level distance, C. C is the distance between the dip-

ping datum point (zero level) and the bottom of the tank.
• Note the distance (mm) from max product level to RTG reference
point.
Note! The G value is defined as positive if the Tank Reference point is located
above the RTG Reference point.
Tank Reference Point
RTG Ref. RTG Reference Point

distance, G
RTG Reference
Tank Reference distance, R
Point
Dipping Datum Point

(Zero Level)
Min. Level distance, C
Figure 1-5 Tank distances.
1-7
1.9 RTG 3920
• Check if there is water at the bottom of the tank.
1.9.2 Visual check
• Free space below the RTG. Normally girders and pipes are not
allowed in the radar beam. If there are disturbing objects below the
antenna, the effect on the current measurement must be carefully
evaluated.
• Check that waveguide, closing and antenna are mounted correctly

and take appropriate actions in order to replace broken parts.
• Diameter of the manhole and the socket height. The socket

must not be higher than 330 mm.
• Note the distance X (mm) between the tank wall and the center of
the RTG. It will be used for calculations of the clearance angle
below the antenna.
1.9.4 Free space requirements
• Check the Clearance Angle plumbline tankwall (arctan X/R). If

the clearance angle is less than 15°, the RTG must be inclined
away from the wall.
Use the 4° flange if the

clearance angle is less
than 15°.
Antenna axis
Antenna axis
30° radar beam

30° radar beam
Vertical plumb
line
Vertical plumb line
Inclination 4° ±1°
Figure 1-6 Inclination.
1-8
• Inclination of RTG. Use

the 4° flange to direct the
radar beam 4° towards
the tank center if the
clearance angle is less
than 15°. For larger
clearance angles, the
gauge should be inclined
0°.
• Sidewise angle:
0 ° ± 1°
(horizontal flange) 5° 5°
Vertical plumb
4 ° ± 1° (4 ° flange) line
R
Free passage
Antenna axis
Clearance angle
X
Figure 1-7 Clearance angle.
Antenna axis
Sidewise angle:
0 ° ± 1° (horizontal flange)
4 ° ± 1° (4 ° flange)
Figure 1-8 Sidewise angle.
1-9
1.10 RTG 3930
• Check if there is water at the bottom of the tank.
1.10.2 Visual check
• Free space below the RTG. Normally girders and pipes are not
allowed in the radar beam. If there are disturbing objects below the
antenna, the effect on the current measurement must be carefully
evaluated.
• Check that waveguide, closing, feeder and parabola are mounted

correctly and take appropriate actions in order to replace broken
parts.
• Diameter of the manhole and the socket height. If a 20" diame-

ter socket is used, the height of the socket must not exceed 0.6 m.
If the manhole is wider, the height of the socket may be corre-
spondingly higher as long as the requirement of a free passage
within 5° is fulfilled.
• Note the distance X between the tankwall and the center of the
RTG. It will be used for calculations of the clearance angle below
the antenna.
Figure 1-9 RTG 3930.
1-10
• Check that the guide

pins on the TRL/2
adapter are directed
towards the center of
the tank. See TankRa-
dar Rex Installation
Manual Ed. 3 rev.B,
chapter 10.2.7 Mount-
ing the Antenna.
5° 5°
• Check the Clearance
Angle between plum-
bline and tankwall Vertical plumb
line
R
(arctan X/R). If the clear-
ance angle is less than
5°, the RTG must be
inclined 1.5° away from Antenna axis Free passage
the wall.
• Inclination. The inclina-

tion of the gauge should
not exceed 1.5° towards
the center of the tank. Inclination 1.5° Clearance angle
RTG 3930 is mounted
X
on the tank nozzle by
using the Flange Ball Figure 1-10 Inclination and Clear-
which make it easy to ance angle.
adjust the inclination.
• Sidewise angle max 0.5°. Check that the flange is horizontal

within 3° along the tank wall.
Antenna axis
Sidewise angle
Figure 1-11 Sidewise angle.
1-11
1.11 RTG 3950
• Check if there is water at the bottom of the tank
1.11.2 Visual check
• Check still-pipe (wildings, burrs, amount of rust, dirt and deposits).
• Check that the RTG 3950 is installed according to the instructions

in the TankRadar Rex Installation Manual, chapter 10. Take
appropriate actions in order to replace any broken parts.
Figure 1-12 RTG 3950 Fixed and Inclined version.
1-12
1.11.3 Still-Pipe Requirements
• Check the number of holes, distance between the holes (unit

meter) and the hole diameter (unit mm). It is important that the
area of the slots and holes not exceed the specified limits, see
Table 1-2.
Pipe Dimension
5 6 8 10 12
(inch)
Max Area of Slots or

Holes (m2) 0,1 0.1 0.4 0.8 1.2
Table 1-2: Maximum area of the slots or holes
• Note the pipe inner diameter. It will be used when the RTG is con-
figured.
• The still-pipe flange must be horizontal within ±2°.
• The still-pipe must be vertical within 0.5° (0.2 m over 20 m).
Note! The topmost hole/slot in the still-pipe must be placed above maximum
product level.
RTG 3950 Fixed Version
620 mm
700 mm
Min. 500 mm
Figure 1-13 Free space requirements RTG 3950 Fixed Version
1-13
RTG 3950 Inclined Version
590 mm
510 mm
Min. 500 mm
A
Pipe Size (in.) A (mm)
5 430
6 448
8 480
10 518
12 545
Make sure that there is sufficient

space to open the cover.
Figure 1-14 Free space requirements RTG 3950 Inclined Version
1-14
1.12 RTG 3960
• Note what type of pressure flange that is used: 150, 300 or 600
PSI. For non-standard antennas this information is needed in
order to configure the Tank Connection Length (TCL). See the
TankMaster Winsetup User's Guide for more information on TCL
configuration. For standard antennas the TCL is automatically
configured and does not need to be changed.
• Make a note if the RTG is equipped with a ball valve.
With Ball Without Ball

TCL
valve valve
150 PSI 870 590
300 PSI 890 610
600 PSI 920 640
Table 1-3: Default TCL values for different pressure flanges.
1-15
1.12.2 Visual check
• Note if the pipe and pins are inspected by a service engineer.
• Check that a deflection plate with calibration ring, and a verifica-

tion pin are mounted.
• Check that the verification pin is aligned towards the flangemark,

see Figure 1-15.
• Check that the waveguide, housing and foam plug are installed
according to the instructions in the Installation Manual, chapter 10.
1.12.3 Still-Pipe
• Note the number of holes, the distance between the holes (unit
meter) and the diameter (unit mm).
• Note the pipe inner diameter.
• Check that the pipe cone fits tightly to the still-pipe.
Still-pipe
Flange mark indicating

the direction of the
Verification pins Align!
Verification pin
Figure 1-15 Align the verification pins.
Note! The topmost hole/slot in the still-pipe must be placed above maximum
product level.
1-16
1.12.4 Verification Pins

Check the position of the Verification pins. The distance is
measured from the RTG Reference Point to the pin.
Verification pin and deflection plate with calibration ring
• The verification pin should be placed at 2000 ±500 mm from the

RTG Reference Point.
• Measure the distance from the top of the bottom plug to the bot-
tom of the tank, see Figure 1-16. This value will be used for the
calibration of the RTG:
• Zero level at tank bottom: adjust the Calibration distance

value until the displayed level (at the calibration ring) is equal
to the distance from calibration ring to tank bottom (see Fig-
ure 1-16).
• Zero level at calibration ring: adjust the Calibration dis-

tance value so the displayed level is equal to zero.
2000 ± 500 mm
Still-Pipe
Verification pin
Calibration ring
Reflector Support
Min. 150 mm
Figure 1-16 Calibration ring (plug) and verification pin.
1-17
Old systems with three verification pins
pin 1: top pin is placed at approximately 95% of the tank height (not
closer than 1.5 m from the flange).
pin 2: at 50% of the tank height.
pin 3: at approximately 20% of the tank height (not less than 0.8 m above
the lower end of the pipe).
If the tank is less than 7 meters high, only two verification pins are used.
Still-pipe
Verification pin
Deflection plate
Figure 1-17 Three verification pins and deflection plate.
1-18
1.13 Rex Configuration
Check that the following items are correct in TankMaster:
• Tank name.
• Check that the Unit ID corresponds to the RTG installed at the cur-
rent tank.
• RTG address corresponds to the address specified in TankMas-

ter.
To view the Unit ID and RTG address:
1 Select the Rex transmitter icon in the WinSetup workspace.
3 Select the Communications tab.
1.13.2 Tank Distances and RTG Geometry
Check that the following tank parameters are correct in TankMaster:
• Tank Reference distance, R (Holding register 1000).
• RTG Reference distance, G (Holding register 1002).
• Calibration distance (Holding register 1004).
• Minimum Level distance, C (Holding register 1006)
• Hold off distance (Holding register 1008)
1-19
To view the tank parameters of a certain device do the following (see

Figure 1-18):
1 Select the Transmitter icon in the WinSetup workspace.
2 Click the right mouse button and choose the Properties option
and view the Tank Distances tab and the RTG Geometry tab.
Figure 1-18 Rex RTG Properties.
1.13.3 Rex configuration
Check the Rex transmitter configuration in TankMaster:
• No of enabled analog inputs and hart devices.
• No of temperature sensors.
• Type of temperature sensors (spot/averaging).
• If Rex emulation, what type.
To view the Rex transmitter configuration:
3 Select the Configuration tab.
1-20
1.13.4 Input Register parameters
Check the following parameters in TankMaster:
• Device (4000) and Measurement status (4002).
• Level (4006) and Ullage (4008).
• Level rate (4010), Signal strength (4012) and Gain (4016).
• Rex program version (Service > Devices > Properties > Com-
munication tab)
Check that Device status (1000), Device error (1002) and Device
warning (1004) shows value 0.
To view input register of a certain device do the following:
2 Click the right mouse button and choose View input registers
option.
3 Choose All.
4 Type for example 1000 as start value in the Start register field
and 10 in the Number of registers.
5 Click the Read button.
See TankMaster WinSetup User’s Guide for a further description on how

to view input registers.
1-21
1.13.5 Calibration
Normally a minor adjustment of the Calibration Distance parameter is

needed in order to fine tune the gauge to match the manual hand dip
value. It is recommended that the Rex gauge is calibrated when the tank
is not full or empty and when there are no movements in the tank.
To calibrate a Rex gauge do the following:
3 Select the RTG Geometry tab.
4 Type a new value in the Calibration Distance field and click the
OK button.
For further instructions, see TankMaster WinSetup User's Guide.
Figure 1-19 Calibration distance.
1-22
1.14 Data Acquisition Unit
• Tank name
• Unit ID
1.14.2 Distance
• Check the distance between the Transmitter Head and the DAU.
The distance must not exceed 50 m.
1.14.3 Cable and Junction box
• A shielded cable connected to ground must be used between the

RTG and the DAU. The shield shall be grounded in both ends. If
an extension cable is used, check that the junction box provides
good shielding too.
• If a junction box is used, make sure that it is marked EExi.
DAU
• Measure between 6-7 with X20 connected and disconnected. The

corresponding values are ~5.5 VDC and ~12VDC, respectively.
• Make a note if the DAU is externally grounded.
1.14.5 Temperature
• Check that the X1, X2 and X3 jumpers are selected according to

the current temperature range. Check that the reference resistor
corresponding to the selected temperature range is used. See
Installation Manual, chapter 4.3.
• Sensors correctly connected
1-23
1.14.6 Software
• Write protection (on/off)
• If you use the DB loader, note the version. Normally, the DB

loader is only used in connection with software upgrading.
• Note which version of the DAU program that is used.
1.15 DAU Configuration
• Tank name
• Check that the Unit ID corresponds to the DAU installed at the cur-
rent tank
• Check that the address corresponds to the address specified in

TankMaster of the current tank.
1.15.2 Temperature Check
• Check that each temperature sensor outputs a correct value.
• Note the average temperature.
1.15.3 Current inputs
• Note the number of current inputs used, and check the measured
values.
1.15.4 Display
• Check that no error codes are displayed.
1-24
1.16 Operator software
1.16.1 TankMaster WinOpi
Note computer related data like:
• Processor
• Clock frequency
• Hard disk space
• RAM
• Com ports used
• Printer type
• Operating system and version
• File system (NTFS, FAT)
• Test the printer report function.
1.16.2 Back-up
Note! TankMaster version and save database registers according to the

checklist for:
• FCU
• Rex
• DAU
To save database registers (holding and input registers) do the

following:
1 Select the transmitter icon in the WinSetup workspace.
2 Click the right mouse button and choose Save database to file
option.
3 Choose Input or Holding register.
4 Choose Predefined (most used registers) or User-defined (lets

you specify which registers to save).
5 Click Browse button and specify a location and a name for the file.
6 Click the Save button.
See TankMaster WinSetup User's Guide for instructions on how to save

database registers.
1-25
1-26
June 2008 Index
Index
B
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
C
C distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Clearance angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9, 1-11
D
Data Acquisition Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Database registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
DAU Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Deflection plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Dipping datum point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
F
FBM 2180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
FCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Field bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3, 1-4
Field bus shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
G
G distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Group bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
H
Hand dip nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Hold off distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
I
Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9, 1-11
Input register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
R
Rex Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
RTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
RTG 3920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
RTG 3930 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
RTG 3950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
RTG 3960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Index-1
Index June 2008
RTG address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

RTG reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7, 1-17
S
Save database registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
Sidewise angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9, 1-11
T
Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Tank reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
TankMaster WinOpi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
U
Unit ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6, 1-19
V
Verification pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17, 1-18
Z
Zero level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Index-2
308011En, Ed.2/Rev.B
June 2008
Rosemount Tank Gauging local representative:
Emerson Process Management

Rosemount Tank Gauging
Box 130 45
SE-402 51 Göteborg
SWEDEN
Tel (International): +46 31 337 00 00
Fax (International): +46 31 25 30 22
E-mail: sales.rtg@Emerson.com
Copyright © Rosemount Tank Radar AB.

Ref. no: 308011En, Ed.2/Rev.B. June 2008.

Manual Tankradar Rex Commissioning Manual Rosemount en 80812

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Manual Tankradar Rex Commissioning Manual Rosemount en 80812

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Commissioning Manual

Copyright © June 2008

Rosemount Tank Radar AB

TankRadar is a registered trademark of Rosemount Tank Radar AB.

HART is a registered trademark of HART Communication Foundation

Any substitution of non-recognized spare parts may jeopardize safety.

Specific FCC Requirements (USA only)

Rosemount TankRadar Rex generates and uses radio frequency energy.

Rosemount TankRadar Rex has been FCC certified under test

1.2 PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 TANK INTERIOR CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 SYSTEM COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 FCU CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.6 FBM 2180 CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.7 COMMUNICATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.8 RTG 3900 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .1-6

1.9 RTG 3920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.10 RTG 3930 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.11 RTG 3950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1.12 RTG 3960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.13 REX CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

1.14 DATA ACQUISITION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23

1.15 DAU CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24

1.16 OPERATOR SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25

1. Checks and Adjustments

Commissioning a Rex system aims at checking the mechanical and

It includes calibrations and adjustments in order to achieve high

Check that the equipment is undamaged and that it corresponds to the

• Delivery no. the system number provided by the project depart-

• Name and location of plant.

• Engineer responsible for the commissioning, and the date when

• Note the tank distances needed for installation and configuration

• Note the addresses to be used for the communication between the

• Check that the correct hardware parts are installed.

• Make sure that you bring appropriate tools and instruments.

1.3 Tank Interior Conditions

1.4 System Composition

Enter the following information about the system:

• System Master. There may be several units acting as master at

• The number of FCUs, FBMs, RTGs and DAUs.

1.5 FCU checklist

1.5.1 FCU information

Note the name, Unit ID

• The FCU is not intrinsically safe. It must therefore be installed in a

• Weather protection: make a note whether the FCU is placed in a

1.5.3 Electrical check

• Grounding: if there is no protective ground in the mains supply

1.5.4 Field bus check

• Shielded cables are required in order to avoid crosstalk if the

• Note the distance if there are two fieldbuses running in parallel.

1.5.5 Group bus check

• Note whether the group bus communicates via the RS-232C or

• Note if redundant FCUs are used.

• Note the FCU program version.

To view the FCU program version:

1 Select the FCU icon in the TankMaster WinSetup workspace.

3 Select the Communication tab.

1.6 FBM 2180 checklist

1.6.1 FBM information

• Note the name and version of each FBM.

1.6.2 Visual check

• Note if the FBM is installed outdoors or in the control room.

• Check if there is anything in the surroundings which may disturb

1.6.3 Field bus check