Rosemount TankRadar Rex 3900 Series Safety Manual
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Rosemount TankRadar Rex 3900 Series Safety Manual

For use in safety instrumented systems
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Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
Safety Manual For Use In Safety Instrumented Systems
P r o d u c t D i s c o n t i n u e d
www.rosemount-tg.com

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Summary of Contents for Rosemount TankRadar Rex 3900 Series

  • Page 1 Safety Manual 308020EN, Edition 1 June 2007 Rosemount TankRadar Rex Safety Manual For Use In Safety Instrumented Systems P r o d u c t D i s c o n t i n u e d www.rosemount-tg.com...
  • Page 3 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 June 2007 Safety Manual Rosemount TankRadar Rex First edition Copyright June 2007 © Rosemount Tank Radar AB www.rosemount-tg.com...
  • Page 4 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. WARNING Do not open the Integrated Junction Box JBi when the circuit is alive.

  • Page 5: Table Of Contents

    Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 June 2007 Contents Contents ..1 COPE AND URPOSE OF THE AFETY ANUAL ......2...
  • Page 6 Rosemount TankRadar Rex Safety Manual 308020EN, Edition 1 Contents June 2007...

  • Page 7: Scope And Purpose Of The Safety Manual

    Scope and Purpose of the Safety Manual The purpose of the safety manual is to document all the information, relating to TankRadar Rex 3900 Series, which is required to enable the integration of TankRadar Rex into a safety- related system, in compliance with the requirements of IEC...

  • Page 8: Reference Documents

    Rosemount TankRadar Rex Installation Manual, Ref. no. 308014EN • Rosemount TankRadar Rex Service Manual, Ref. no. 308012EN • Rosemount TankRadar Rex Special Safety Instruction, Ref. no. 308016E • TankMaster WinSetup User’s Guide, Ref. no. 303027EN • Rosemount TankRadar REX Technical Description,...

  • Page 9: Scope Of The Product

    June 2007 Scope of the Product Purpose of the Product The Rosemount TankRadar Rex 3900 Series is designed for high performance level gauging in various types of storage tanks. Temperature sensors, remote display unit, water level sensors, pressure sensors, and other devices can be connected. Two relays are available for alarm indication and overfill and dry run protection.
  • Page 10 Rosemount TankRadar Rex Safety Manual Chapter 3 Scope of the Product 308020EN, Edition 1 June 2007 TankRadar Rex is equipped with two cable outputs for intrinsically safe and non-intrinsically safe connections, respectively. Wires are clearly marked with numbers and designation of wires is shown on a printed plate at the cable outputs.
  • Page 11 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 3 Scope of the Product June 2007 relay K1 relay K1 relay K1 relay K2 Figure 2. Connecting to the relay ports via Integrated Junction Box (JBi). Note! Depending on system configuration one or two relays are available.
  • Page 12 Rosemount TankRadar Rex Safety Manual Chapter 3 Scope of the Product 308020EN, Edition 1 June 2007 3.3.2 Safety Function Using Two Relays in Series This Safety Function is based on the two relay outputs coupled in series used as the primary safety variable for overfill and dry run protection.

  • Page 13: Parameters Related To Safety Functions

    Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 3 Scope of the Product June 2007 Parameters Related to Safety Functions TankRadar Rex is classified as a Type B device having a hardware fault tolerance of 0. The TankRadar Rex is available with one or two relays.
  • Page 14 Rosemount TankRadar Rex Safety Manual Chapter 3 Scope of the Product 308020EN, Edition 1 June 2007 of IEC 61511 First Edition 2003-01 section 11.4.4, the hardware fault tolerance of a device may be reduced by 1. A third-party assessment conducted by exida.com of the TankRadar Rex has shown that the requirements of the IEC 61511 First Edition 2003-01 section 11.4.4 are fulfilled and that the...
  • Page 15 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 3 Scope of the Product June 2007 • The instrument utilizes Fixed Program Language (FPL) • The estimated useful lifetime of electrolytic capacitors is > 20 years. As the capacitors are the limiting factor with regard to useful lifetime of the system, the useful lifetime of the product is considered to be 20 years.
  • Page 16 Rosemount TankRadar Rex Safety Manual Chapter 3 Scope of the Product 308020EN, Edition 1 June 2007 3.4.2 Parameters Related to Safety Function Using Two Relays A Failure Modes, Effects and Diagnostics Analysis (FMEDA) was conducted resulting in failure rates according to Table 5:...
  • Page 17 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 3 Scope of the Product June 2007 However, the decision on the usage of Proven-in-use devices is always with the end-user. According to IEC 61508 the average Probability of Failure on...

  • Page 18: Hardware And Software Configuration

    Software version 1.G4 and higher • Serial numbers > 42315 Unless specified at the time when purchasing the TankRadar Rex, please contact Emerson Process Management/Rosemount Tank Gauging to verify that the gauge can be considered within the scope of the assessment by exida.com.

  • Page 19: Installation And Configuration

    Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 4 Installation and Configuration June 2007 Installation and Configuration Please refer to the following documentation for instructions on how to install and configure the TankRadar Rex gauge: • REX Installation Manual, Ref. no. 308014E •...

  • Page 20: Configuration With One Relay

    Rosemount TankRadar Rex Safety Manual Chapter 4 Installation and Configuration 308020EN, Edition 1 June 2007 Configuration with One Relay In the following description configuration of relay K1 is used as an example. The same procedure applies for relay K2. The relay K1 is configured by using the REX Relay Output 1 configuration window, see Figure 4 (REX Relay Output 2 window applies for relay K2).
  • Page 21 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 4 Installation and Configuration June 2007 Figure 4. Configuration of relay output in TankMaster WinSetup. The overfill and dry run protection safety function requires that you choose Level or Ullage as relay output source. Choose the desired option from the Select Source drop-down list.
  • Page 22 Rosemount TankRadar Rex Safety Manual Chapter 4 Installation and Configuration 308020EN, Edition 1 June 2007 Tank Reference Point RTG Reference Distance (G) RTG Reference Point Hold Off Tank Ullage distance RTG Ullage RTG Reference Point Tank Reference Height (R) Level...

  • Page 23: Configuration When Using Two Relays In Series

    Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 4 Installation and Configuration June 2007 Configuration When Using Two Relays In Series When two relays are used they must be connected as illustrated in Figure 3. Each relay is configured separately using the REX Relay Output 1 and the REX Relay Output 2 configuration windows, see Figure 6 and Figure 7.
  • Page 24 Rosemount TankRadar Rex Safety Manual Chapter 4 Installation and Configuration 308020EN, Edition 1 June 2007 Figure 6. Configuration of Relay Output 1. The overfill and dry run protection safety function requires that you choose Level or Ullage as relay output source. Choose the desired option from the Select Source drop-down list.
  • Page 25 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 4 Installation and Configuration June 2007 When relay 1 is configured, continue with the relay 2. In the Win- Setup workspace, click the right mouse button on the REX gauge icon, and select Properties.

  • Page 26: Verification Of The Safety Function

    To write protect the TankRadar Rex gauge, either an internal or an external switch can be used (see the Rosemount TankRadar Rex Service Manual for further information). The internal switch is located on a circuit board in the transmitter head:...
  • Page 27 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 4 Installation and Configuration June 2007 The TankRadar Rex can also be equipped with an optional external metrological seal, see Figure 9. In this case the gauge housing does not need to be opened to enable the write protection.

  • Page 28: Proof Tests

    Note if there are any objects like beams, heating coils, etc. which correspond to the found echoes. If the disturbing echoes affect measurement performance, appropriate action has to be taken. Please contact Emerson Process Management/Rosemount Tank Gauging for advice.

  • Page 29: Hand Dipping

    Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 5 Proof Tests June 2007 The overfill and dry run protection function should be checked by testing the system response when the product level reaches the relay set point (see “Configuration with One Relay” on page 14).
  • Page 30 Rosemount TankRadar Rex Safety Manual Chapter 5 Proof Tests 308020EN, Edition 1 June 2007 To manually switch between different relay states do the following: Select a Rex gauge in the TankMaster WinSetup Workspace win- dow: Manual Control Relay Click the right mouse button and choose the Manual Control...

  • Page 31: Repair

    Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Chapter 5 Proof Tests June 2007 Choose Manual in the Control Mode pane. Choose a new relay state from the Select New State list. You should test switching between Normal and Alarm to verify that the relay responds in a proper way.

  • Page 32: Terms And Definitions

    Rosemount TankRadar Rex Safety Manual Appendix 308020EN, Edition 1 June 2007 Terms and Definitions Failure in Time (1 FIT = 1failure/10 FMEDA Failure Modes, Effects and Diagnostics Analysis Hardware Fault Tolerance Average probability of Failure on Demand Safe Failure Fraction summarizes the fraction of fail-...

  • Page 33: Appendix Fmeda And Proven-In-Use Assessment

    Appendix FMEDA and Proven-in-use Assessment FMEDA and Proven-in-use Assessment Project: Level Transmitter TankRadar Rex, Radar Tank Gauge RTG 3900 Series Customer: ROSEMOUNT TANK RADAR AB Gothenburg Sweden Contract No.: SAAB Q06/06-26R1 Report No.: SAAB Q06/06-26R1 R003 Version V1, Revision R0, February 2007 Stephan Aschenbrenner, Otto Walch The document was prepared using best effort.
  • Page 34 The proven-in-use investigation was based on field return data collected and analyzed by ROSEMOUNT TANK RADAR AB. This data cannot cover the process connection. The proven-in-use justification for the process connection still needs to be done by the end-user.
  • Page 35 Safety Manual Rosemount TankRadar Rex 308020EN, Edition 1 Appendix June 2007 According to the requirements of IEC 61511-1 First Edition 2003-01 section 11.4.4 and the assessment described in section 6, the level transmitter TankRadar Rex, Radar Tank Gauge RTG 3900 Series with a hardware fault tolerance of 0 and a SFF of 60 % to < 90% is considered to be suitable for use in SIL 2 safety functions.
  • Page 36 Rosemount TankRadar Rex Safety Manual Appendix 308020EN, Edition 1 June 2007 The failure rates listed above do not include failures resulting from incorrect use of the level transmitter TankRadar Rex, Radar Tank Gauge RTG 3900 Series, in particular humidity entering through incompletely closed housings or inadequate cable feeding through the inlets.
  • Page 38 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.srt@emersonprocess.com www.rosemount-tg.com Copyright © Rosemount Tank Radar AB. Ref. no: 308020E, Edition 1. June 2007.

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