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Operation & Maintenance Manual

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Operation & Maintenance Manual

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Operation & Maintenance Manual

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Operation & Maintenance Manual

Operation & Maintenance Manual


Digital Microwave Tank Gauge

8900d Digital Radar

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Operation & Maintenance Manual

Table of Contents
1. About This Documents ............................................................................................................................................6
1.1. Function...........................................................................................................................................................6
1.2. Target Group ...................................................................................................................................................6
1.3. Symbolism Used ..............................................................................................................................................6
2. Your Safety Frist ......................................................................................................................................................7
2.1. Authorised Personnel ......................................................................................................................................7
2.2. Appropriate Use ..............................................................................................................................................7
2.3. Warning about Misuse. ...................................................................................................................................7
2.4. General Safety Instructions. ............................................................................................................................7
2.5. CE Conformity .................................................................................................................................................7
2.6. Safety Information for Ex Areas ......................................................................................................................7
2.7. Manufacturing Declaration .............................................................................................................................8
2.8. Environmental Instructions .............................................................................................................................9
3. Product Description ................................................................................................................................................9
3.1. Configuration...................................................................................................................................................9
3.1.1. Configuration Options .............................................................................................................................9
3.1.2. Scope of Delivery ...................................................................................................................................10
3.1.3. Components ..........................................................................................................................................10
3.1.4. Area of Application ................................................................................................................................10
3.1.5. Functional Principle ...............................................................................................................................10
3.1.6. Power Supply and Bus Communication ................................................................................................11
3.2. Adjustment ....................................................................................................................................................11
3.3. Storage and Transport...................................................................................................................................11
3.3.1. Packaging ...............................................................................................................................................11
3.3.2. Storage and Transport Environment .....................................................................................................12
3.4. Disposal .........................................................................................................................................................12
3.4.1. WEEE Directive 2012/19/EU .................................................................................................................12
4. 8900d Configruation .............................................................................................................................................12
5. 8900d Operation ...................................................................................................................................................12
5.1. Retention of Configuration ...........................................................................................................................12
5.2. Start up ..........................................................................................................................................................13

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5.3. Watchdog ......................................................................................................................................................13


5.4. Shutdown ......................................................................................................................................................13
6. Maintenance .........................................................................................................................................................13
6.1. Planned Preventative Maintenance ..............................................................................................................13
6.2. Gauge Sub-System and Components ............................................................................................................14
6.2.1. Radar Gauge 8900d ...............................................................................................................................14
6.2.2. Rack assembly with power supply and terminals .................................................................................14
6.2.3. CFE Microwave Module ........................................................................................................................14
6.3. Fault Finding ..................................................................................................................................................15
6.4. Specification ..................................................................................................................................................16
6.5. 8900d Level Configuration ............................................................................................................................17
6.5.1. Preparation............................................................................................................................................17
6.5.2. Configuration of Level Measurement ...................................................................................................17
6.5.3. Level Integration ...................................................................................................................................18
6.5.4. Level Persistence ...................................................................................................................................18
6.6. Temperature Configuration ..........................................................................................................................19

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Operation & Maintenance Manual

1. About This Documents


1.1. Function
These operating instructions manual has all the information you need for quick setup and safe operation.
Please read this manual before you start setup.

1.2. Target Group


These operating instructions manual is directed to trained, qualified personnel. The contents of this manual
should be made available to these personnel and put into practice by them.

1.3. Symbolism Used


Information, tip, note This symbol indicates helpful additional information.

Caution: If this warning is ignored, failures or malfunctions can be caused.

Warning: If this warning is ignored, damage to persons and/or serious instrument damages can be caused.

Danger: If this warning is ignored, serious injury of persons and/or damage of the instrument can be the
cause.

Ex applications - This symbol indicates special instructions for Ex applications.

• List - The dot set in front indicates a list with no implied sequence.

→ Action - This arrow indicates a single action.

1 Sequence - Numbers set in front indicate successive steps in a procedure

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2. Your Safety Frist


2.1. Authorised Personnel
All operations described in these operating instructions manual must be carried out only by trained
specialist personnel authorised by the operator. For safety and warranty reasons, any internal work on the
instruments must be carried out only by personnel authorised by the manufacturer.

2.2. Appropriate Use


8900d is a sensor for continuous level measurement. Detailed information on the application range of
8900d is available in chapter "Product description".

2.3. Warning about Misuse.


Inappropriate or incorrect use of the instrument can give rise to application-specific hazards, e.g. vessel
overfill or damage to system components through incorrect mounting or adjustment.

2.4. General Safety Instructions.


8900d is a high-tech instrument requiring the strict observance of standard regulations and guidelines. The
emitting frequencies of all radar sensors are in the x-band range. The low transmitting power is far below
the internationally permitted limit values, and when used correctly, no health-endangering effects are to
be expected. The instrument can also be used without restriction on the side of metallic, closed vessels.
The user must take note of the safety instructions in these operating instructions manual, the country-
specific installation standards as well as all prevailing safety regulations and accident prevention rules.

2.5. CE Conformity
8900d is in CE conformity with ATEX directive 94/9/EC.

2.6. Safety Information for Ex Areas


Please note the Ex-specific safety information for installation and operation in Ex areas. These safety
instructions are part of the operating instructions manual and come with the Ex approved instruments.

WARNING: The user shall ensure that the PTFE parts located within the potentially zone 0 atmosphere are
protected from impact or friction from the flow of non- conductive media and are not exposed to positive
pressures in excess of 60mBar.

WARNING: The user shall ensure that aluminium parts located within the potentially zone 0 atmosphere
are protected from impact or friction

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2.7. Manufacturing Declaration


In conformity with BS EN 60079-14:2008 Radar Gauge 8900d is suitable for use in Zone 1.

The operator must use the instrument as it is intended to be used and follow the specifications of the
following documents:

• These operating instructions manual


• This manufacturer declaration
• The applicable local, national and international installation regulation.

Max. increase of the surface temperature during operation: 9.5oC (individual components in the
instrument).

With an ambient temperature of +45°C on the housing. The maximum ambient temperature during
operation is +135°C

Measures for maintaining explosion protection during operation:

• Operate the instrument in the range of the specified electrical limit values. Permissible supply
voltage: see "Technical data"
• Mount and operate the instrument in such a way that no ignition danger is expected by
electrostatic charges. Make sure that the seals are mounted correctly between the housing and the
two end covers. Screw the covers on tightly.
• If you intend to operate the instrument with open cover make sure that the instrument is in a Zone
where there is there is no explosive atmosphere.
• Make sure that the cable glands are tight and strain-relieved. The outer diameter of the connection
cable must be adapted to the cable gland. Tighten the pressure screw of the cable gland carefully.
• Cover unused openings for cable glands tightly.
• Mount the instrument in such a position that the sensor cannot touch the vessel wall or vessel
installations. Keep the influences of product movements in the vessel in mind.
• The surface temperature of the housing must not exceed the ignition temperature of the
surrounding explosive atmosphere

This instrument was judged by a person that fulfils the requirements according to BSE EN 60079-14

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2.8. Environmental Instructions


Protection of the environment is an important duty common to everyone. Please help to fulfil this
obligation by observing the environmental instructions in this manual:

• Chapter 3.3. "Storage and transport"


• Chapter 3.4. "Disposal

3. Product Description
3.1. Configuration

3.1.1. Configuration Options


8900d primary function is level measurement. However, 8900d also features auxiliary inputs for
measurement of temperature, density and has discrete inputs and outputs for the monitoring and
control of auxiliary devices, for complete inventory control

8900d is available with the following options, specified at the time of order:

Power supply • 20-28Vdc


• 88-264AC 47-64Hz
Antenna • Still pipe Transitions 2”, 6”, 8”
Auxiliary inputs Input 1, 2, 3, 4
For each input specify
• Discrete, un-isolated, standard
• Discrete, optically isolated, option
• Analogue, 4-20mA, option
Process pressure rating For use in atmospheric tanks (up to 60mBar)
Process connection 2”, 3”, 4”, 6”, 8”, 10”, 12”, 18”, 24” as required
Enclosure • Standard: Aluminium LM25
• Option: Stainless Steel AISI 316
Product Temperature • None
measurement • Single spot measurement (specify Pt or Cu)
• Vertical averaging probe (specify Pt or Cu)
• Vertical multi-spot probe (specify Pt or Cu)
Water interface • None
measurement • Standalone Water Probe, option
• Water Probe integrated into Vertical temperature probe, option
Density measurement • None
• Pressure Transmitter (atmospheric tanks)
• Two pressure transmitters (pressurised tanks)

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3.1.2. Scope of Delivery


8900d is delivered as follows, unless specified otherwise within your contract documentation.

• 8900d Radar Tank Gauge


• Process Connection
• Documentation
• This User Guide
• Ex Safety Instructions
• If necessary, Ex or other certificates
• Remote Display option, if specified
• Temperature Probe option, if specified
• Water Interface option, if specified
• Density Measurement option, if specified

3.1.3. Components
8900d consists of the following components:

• Main instrument housing, with electronics and microwave modules


• Front and rear housing covers and fastenings
• Horn or other antenna
• Process Connection

3.1.4. Area of Application


8900d is a radar sensor in X-band (emitting frequency approximately 10GHz) for continuous level
measurement.

8900d performance is optimised for the accurate measurement of product level in storage tanks at
bulk liquid storage facilities, particularly oil terminals, refineries and distilleries and features a range of
antenna sizes for use in free space and still-pipe installations

3.1.5. Functional Principle


The radar sensor emits a continuous signal that varies linearly in frequency over a precise range in a
precise time interval. This signal is reflected by the product and received back into the radar sensor.

Figure 1: Linear Frequency

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The radar sensor compares the transmitted and received signals and calculates the difference in
frequency between them. This frequency is proportional to the range (R) from the sensor to the liquid
surface. Because the sensor is programmed with the value of the range of the tank when empty (E) it
calculates the product level (L) by simple subtraction L = E – R

3.1.6. Power Supply and Bus Communication


8900d may be powered by:

• 24Vdc run along with the bus communications signal in a four-wire cable, or
• A three-wire cable carrying ac-power (L, N, E) and separate to the two-wire cable carrying bus
communications

3.2. Adjustment
8900d may be adjusted with:

• MTG 3700 Tank Gauging Software (PC-based) (Details of 8900d radar adjustments can be found in
details in system start up manual)

All adjustments made are automatically saved to the non-volatile memory of the gauge

3.3. Storage and Transport

3.3.1. Packaging
Your instrument was protected by packaging during transport.

Wherever possible this packaging will consist of environmentally–friendly, recyclable materials.

Please dispose of packaging materials via appropriate recycling facilities.

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3.3.2. Storage and Transport Environment


In transit and in storage your instruments should not be exposed to environmental conditions outside
of the following ranges:

Temperature: -20 to +55oC

Relative Humidity: 20 to 85%

3.4. Disposal
The instrument consists of materials which can be recycled by specialised recycling companies. We use
recyclable materials and have designed the electronics to be easily separable.

Correct disposal avoids negative effects on humans and the environment and ensures recycling of useful
raw materials.

Materials: see chapter "Technical data"

If you have no way to dispose of the old instrument properly, please contact us concerning return and
disposal

3.4.1. WEEE Directive 2012/19/EU


This instrument is not subject to the WEEE directive 2012/19/EU and the respective national laws. Pass
the instrument directly on to a specialised recycling company and do not use the municipal collecting
points. These may be used only for privately used products according to the WEEE directive.

4. 8900d Configruation
The gauge has no moving parts. All configuration and adjustment are carried out by modifying the ‘picture’
of the tank seen by the radar.

This is achieved by modifying the data stored within the memory registers of the gauge.

Registers values may be changed by any of three means:

• Using the Gauge Registers display of the MTG 3700 Tank Gauging System (PC & MS-Windows based
software as shown in the figures below)
• Note: details can be found in System Start up and configuration procedure as well.

5. 8900d Operation
The gauge requires no manual intervention during normal operation.

5.1. Retention of Configuration


The gauge stores all of its configuration in non-volatile RAM and is therefore retained by the gauge
continuously, even during power loss

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5.2. Start up
On applying or restoring power the gauge will initialise and automatically begin to perform all of its
functions including:

• Measurement of level
• Measurement of temperature
• Measurement of water interface
• Communication with host computer
• Display of readings at tank top and tank base
• Input monitoring and output actuation

5.3. Watchdog
The gauge continuously monitors its own performance and will reboot if a change in the 1/100ths of a mm
reading is unchanged for 30 readings. The Up Time Counter register (5Eh) records the number of hours that
the gauge has been running since last reboot.

5.4. Shutdown
The gauge may be shut down by isolating power from the gauge at the tank top.

6. Maintenance
The gauge is a solid-state device with no moving parts and as such requires little maintenance of parts. The
following sections therefore discuss

• Recommended practices for maintaining the gauge in good electrical and mechanical condition
(planned preventative maintenance)
• The assembly of the gauge, identifying the main sub systems and their interconnection
• Fault finding techniques and component recognition in the event of the gauge developing problems
in use

6.1. Planned Preventative Maintenance


The following should be conducted annually

• Turn the gauge off scan at the host system.


• Electrically isolate the gauge.
• Remove the gauge covers and check all electrical connections are sound.
• Check that the cover seals are fitted correctly and are in good condition, if not then replace.
• Check that the cable glands are sound, fully secure and that the sleeve of the connected cable is
correctly housed into the gland.
• Refit the covers and restore power to the gauge.
• At the host system put the gauge back on scan.
• Verify from the RSS register (0Ah) that the return signal strength is adequate (>100). If not check
the antenna system is clean and free from contamination / product build up.
• Confirm gauge accuracy to a manual dip.
• Print and record gauge register values.

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6.2. Gauge Sub-System and Components

6.2.1. Radar Gauge 8900d


• Rack assembly with power supply and terminals and containing
o DDS PCB (generates FMCW sweep)
o DSP PCB (central processor signal conditioning for comms and I/O
o Temperature / RDU PCB (intrinsically safe circuits for temperature probe monitoring
and remote display)
• Enclosure and covers (Ext certified)
• CFE microwave module (transmits and received the radar signal into and from the tank via the
antenna)
• Antenna

6.2.2. Rack assembly with power supply and terminals

Figure 2: Front of Rack Figure 3: Rear of Rack

6.2.3. CFE Microwave Module

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6.3. Fault Finding


Symptom Possible causes
No display at gauge head, no RDU • Gauge has lost mains power supply (mcb tripped, fuse blown,
display, no comms to host computer mains supply down)
• Power isolator turned OFF at tank top
• Gauge internal ac/dc supply has failed
• Gauge internal 5V dc supply has failed
No comms to host computer, but • Comms isolator turned OFF at tank top
gauge is working locally at tank top • Gauge address register (06h) has been changed
• Terminal board fault
• Ribbon cable connection between Terminal Board and I/O board
No display at tank top but comms to • Display PCB fault
host computer is OK. • Ribbon cable connection between Display PCB and Backplane
PCB
Intermittent or faulty temperature • Element failed in temperature probe
readings • Bad cable connection between temperature probe and gauge
• Ribbon cable fault between terminal board and
Temperature/RDU PCB
• Faulty temperature/RDU PCB
Level reading fluctuates wildly across • Faulty DDS PCB
height of tank • Cable fault between DDS and CFE
• Cable fault between DFE and DSP
• Cable fault between power supply and CFE
• Loss of 5V power supply to CFE
• Faulty CFE
• Antenna is contaminated to extent that radar beam is absorbed

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6.4. Specification
GENERAL DESCRIPTION High Accuracy Microwave Tank Gauge –
Non-intrusive FMCW radar level detection with auxiliary inputs
For temperature, density and water interface
APPLICATION Custody Transfer / Inventory Management
Problematic Petrochemicals

PERFORMANCE Level Accuracy ± 1mm


Level Measuring Range 0-40 Metres
Temperature Accuracy ± 0.1oC (from Spot/Multiple Averaging/Multiple Spot
Probe)
Temperature Measuring Range -50oC to +200oC
ELECTRICAL Electrical Safety
II 1/2G EEx d [ia] IIB T4 (tamb = -20oC to +45oC)
Power Supply 15-24Vdc
88-264 Vac 47-64 Hz
Power Consumption Less than 12 Watts
Microwave Emissions Less than 0.1m W/cm2
Lightning Protection Full Galvanic and Optical Isolation to 5kA

COMMUNICATION & Host communications Electrical Interface RS485 2-wire half duplex
CONTROL SYSTEMS Protocols Modbus RTU, MTG proprietary
Alarm Outputs 4 off Digital Outputs
Auxiliary Inputs 4 Inputs, each with the following option
• Discrete, un-isolated
• Discrete, optically isolated
• Analogue, 4-20mA
Temperature 12 RTD inputs from Spot/Multiple
Averaging/Multiple Spot Probe, Cu or Pt elements
Integral Display Illuminated Graphics Display Panel with selectable
display
PHYSICAL Exterior Protection Standard: Aluminium LM25
Option: Stainless Steel AISI 316
Environmental Protection IP67/NEMA 4
Tank Operating Temperature -40oC to +200oC
Working Pressure Atmospheric (up to 60mBar)
Weight 26Kg
Process Connection 2”, 3”, 4”, 6”, 8”, 10”, 12”, 18”, 24” as required
Antenna Sizes Free space horns (horn external diameter in mm):
• 6” (146 mm)
• 8” (194 mm)
Parabola: 425mm diameter dish
Still pipe transitions:
• 2” NB pipe
• 6” NB pipe
• 8” NB pipe

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6.5. 8900d Level Configuration

6.5.1. Preparation
Measure the vertical distance from the top of the process connection to the base of the tank. Note this
as the TANK HEIGHT.

Ascertain and record the MAXIMUM WORKING LEVEL of the tank.

WARNING: This is the working range of the tank, above which the product level will never rise and
above which the product level will never be required to be measured.

Ascertain and record the MINIMUM WORKING LEVEL of the tank. This is the level below which the
tank will lose suction and below which the tank is considered to be EMPTY.

For tanks with still pipes ascertain and record the INTERNAL DIAMETER of the still pipe.

Ascertain and record the current PRODUCT LEVEL in the tank, e.g. By manual dip. Ideally the tank
should be half full when taking this measurement.

Ascertain and record the DIELECTRIC CONSTANT of the product stored within the tank

6.5.2. Configuration of Level Measurement


All values are in mm unless otherwise stated.

1. Enter the measured TANK HEIGHT into the Tank Height register (00h).
2. Enter the MAXIMUM WORKING LEVEL into the Maximum Working Level register (10h).
3. Enter the MINIMUM WORKING LEVEL into the Minimum Working Level register (6Eh).
4. Enter values into the P FACTOR (61h) and K FACTOR (61h) registers according to the value of the
DIELECTRIC CONTACT of the product in the tank and in accordance with the following table:

Dielectric Constant K Factor P Factor


>3 1000 500
<=3 2000 500
Still pipe 0 0

5. For still pipe mounted radar gauge enter a still pipe factor into register M (1Eh) based on the
INTERNAL DIAMETER of the still pipe as follows (based on sched. 40 pipe):

Nominal pipe size Internal dia. (mm) M value


2” 52.5 7110
6” 154.2 9683
8” 202.7 9820
For other internal diameters consult MTG.

6. The gauge will deliver a product level in the Level register (01h).
7. Subtract the measured PRODUCT LEVEL from the new value in the Level register (this may be a
negative value).

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8. Add 10000 to this value and enter the resulting value in the Offset register (19h). This should result
in the Level register containing the same value as the measured PRODUCT LEVEL.
9. Now calculate the value of Tank Height + Offset – 10000 – Maximum Working Level. Enter the
resulting value in the Range Inhibit Min register (17h).

WARNING: The Range Inhibit Min register should never be set such that its value exceeds the value of
(Tank Height + Offset – 10000 – Maximum Working Level) as this will impact the gauge’s ability to
measure at high product levels.

10. Calculate the value of Tank Height + Offset - 9000. Enter the resulting value in the Range Inhibit
Max register (1Fh).
The gauge should now be reading the correct product level

6.5.3. Level Integration


For tanks that are turbulent in use it may be preferable to apply averaging to the reported level value.

To turn on integration, enter the required averaging array size into the Level Array Max register (68h).
A value of 0 turns averaging off. E.g. A value of 5 will integrate the newest recorded level along with
the last 4 recorded levels.

WARNING: Setting the Level Array Max value too high may result in the reported level lagging behind
the actual tank level. Values greater than 5 should be used with caution

6.5.4. Level Persistence


For tanks where the liquid surface may be so turbulent as to be intermittently dispersed to the view of
the radar then level persistence may be applied.

Level persistence prevents the gauge from selecting a new target level outside a set tolerance until that
new target has been read persistently for a number of counts.

To enable level persistence:

Set the Level Tolerance register (69h) to a value that level change must exceed before the level will
consider moving (e.g. 20).

Set the Level Tolerance Count Max register (67h) to a value that represents the number of successive
readings that the level must change for before moving to the new level (e.g. 5).

To disable level persistence set the Level Tolerance and Lover Tolerance Count Max registers to zero.

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6.6. Temperature Configuration


Ascertain the temperature probe element type and note the associated value:

Platinum (16)

platinised-copper (0)

Ascertain the temperature probe type and note the associated value:

Multiple Averaging Probe (0)

Single Spot Probe (1)

Multiple Spot Probe (2)

Add the value of the two code types together and enter the resulting value into the Temp type
register(12h).

e.g.

A platinised-copper multiple averaging probe would result in a value of 0 in the Temp Type register.

A platinum spot probe would result in the value 17 in the Temp Type register.

For multiple spot probes or multiple averaging probes ascertain the number of bulbs in the probe.

If the last probe is probe X then change the value of register Temp X Height to equal or exceed the value of
the Tank Height register (registers 2Fh – 3Ah).

The Temperature register (1Ch) should now read the correct temperature value in units of 0.1oC (e.g.
22.5oC would appear as register value 225

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