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IOM027FVAE0804 7532 Radar Tank Gauge Smart transmitter for continuous and non-contact precision level measurement. For custody transfer and inventory-control applications with NMI and PTB approval. Installation and Operations Manual 5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA www.varec.com Varec, Inc.
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An overview of all device functions can be found on page 96. A description of the device functions for the 7532 RTG can also be found on the enclosed CD-ROM. history...
Safety Instructions The Varec Model 7532 Radar Tank Gauge (RTG) is a compact radar level transmitter for the continuous, contactless measurement of liquids, pastes and sludge in stilling wells. The device can also be freely mounted outside closed metal vessels because of its operating frequency of about 6 GHz and a maximum radiated pulsed energy of 1mW (average power output 1 µW).
7532 The following procedures must be carried out before a transmitter is sent to Varec for repair: • Always enclose a duly completed “Declaration of contamination” form. Only then can Varec transport, examine and repair a returned device. • Enclose special handling instructions if necessary, for example a safety data sheet as per EN 91/155/EEC.
Device certified for use in explosion hazardous area If the 7532 RTG has this symbol embossed on its name plate it can be installed in an explosion hazardous area Explosion hazardous area Symbol used in drawings to indicate explosion hazardous areas.
7532 2.1.1 The following technical data are given on the instrument nameplate: Figure 1: Figure 2: Figure 3: Identification Device designation Nameplate and Certification Plates Information on the nameplate of the 7500 RTG (example) Information on the NMi type plate for custody transfer applications of the...
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Identification 2.1.2 Ordering structure 7532 RTG Ordering structure Certificates A For non-hazardous areas IS - Class I, Division 1, Group A-D U CSA IS - Class I, Division 1, Group A-D 1 ATEX II 1/2 G EEx ia IIC T6, note safety instruction (XA) for electrostatic charg-...
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7532 7532- Output and operation A 4…20 mA HART with VU 331, 4-line alphanumeric dis- play Special version Housing C Aluminium T12-housing with separate connection compartment, coated, IP65 Y Special version Gland / Entry 2 M20x1.5 cable gland 4 ½ NPT cable entry...
Identification Caution! It is essential to follow the instructions concerning the unpacking, transport and storage of measuring instruments given in the section “Incoming acceptance, transport, storage” on page 12. The scope of delivery consists of: • Assembled instrument • ToF Tool (operating program) •...
No special alignment is required. However, make sure that the planar antenna is installed vertically relative to the stilling well axis. Note! The 7532 RTG with planar antenna is designed for use on stilling-wells only! Mounting Quick installation guide Mounting Turn housing...
Mounting 3.2.1 Check the packing and contents for any signs of damage. Check the shipment, make sure nothing is missing and that the scope of supply matches your order. 3.2.2 Caution! Follow the safety instructions and transport conditions for instruments of more than 18 kg.
• Depending on its consistence, foam can either absorb microwaves or reflect them off the foam surface. Measurement is possible under certain conditions. 7532 RTG (planar) Behaviour if measuring range is exceeded The behaviour in case of the measuring range being exceeded can be freely set: the default setting is a current of 22 mA and the generation of a digital warning (E681).
B to ensure a reliable measurement. Product class 1)Treat Ammonia NH3 as a medium of group A, e.g. always use a stilling well. Measuring range depending on product class for 7532 RTG: Product class max. measuring range with custody transfer approvals ε...
Max. Level Blocking distance (BD) Note! Inside the blocking distance a reliable measurement can not be guaranteed. 20 mA 100% Stilling well / Bypass 7532 RTG from Flange 1 m/40" Radar Tank Gauge Installation and Operations Manual...
• Select antenna extension as big as possible. For intermediate sizes (e.g. 180 mm) select next larger antenna extension and adapt it mechanically. Maximum gap allowed between the antenna/horn of 7532 RTG and the inside of the stilling well is 5 mm (3/ 16").
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Mounting Radar Tank Gauge Examples for the construction of stilling wells 7532 RTG 7532 RTG Installation and Operations Manual...
7532 3.4.3 After mounting, the housing can be turned 350° in order to simplify access to the display and the terminal compartment. Proceed as follows to turn the housing to the required position: • Undo the fixing screws (1) • Turn the housing (2) in the required direction •...
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Mounting 3.4.4 Installation tips Varec UNI flanges are designed for non-pressurized operation respectively max. 1 bar absolute pressure. The number of bolts has sometimes been reduced. The bolt-holes have been enlarged for adaption of dimensions, therefore, the flange needs to be properly aligned to the counterflange before the bolts are tightened.
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7532 Mounting Preparation for the installation of the Varec UNI flange...
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Mounting pull off housing mount Varec UNI flange Varec UNI flange (max. 1 bar) detail A: flange adapter (see under) detail A flange hub for the connection to flanges provided by the customer mounting: 4 bolts M6 / 90˚ Ø 78 e.g.
7532 3.4.5 Installation tips For control and cleaning purposes as well as for hand dipping (tape), a sample hatch gauging is recommended. The sensor head can be easily checked in the area of the opening. Manual gauging with gauge rod or tape is possible without removal of the transmitter.
Mounting 3.4.6 Installation tips The Pivoting element serves to swivel the 7500 RTG from the measuring position, e.g. to clean the antenna or dip the tank. The pivoting element is not part of the standard offering from Varec, special offers available under ref.
7532 Wiring Wiring Quick wiring guide When grounding conductive screens, the corresponding directives EN 60079-14 and EN 1127-1 must be observed. Recommendation for safe grounding of conductive screens: Wiring...
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Wiring " Before connection please note the following: ● The power supply must be identical to the data on the Caution! nameplate (1). ● Switch off power supply before connecting up the device. ● Connect Equipotential bonding to transmitter ground terminal before connecting up the device.
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7532 Wiring with Tank Side Monitor 4590 " Before connection please note the following: ● The power supply must be identical to the data on the Caution! nameplate (1). ● Switch off power supply before connecting up the device. ●...
Wiring Terminal compartment The housing comes with a separate terminal compartment. Load HART Minimum load for Hart communication: 250 Ω Cable entry Cable gland: M20x1.5 or Pg13.5 Cable entry: G ½ or ½ NPT Supply voltage Direct current voltage: 16…36 VDC Communication Power supply Signal...
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7532 4.2.1 See page 27. 4.2.2 - ToF Tool FXA 193 4.2.3 - ToF Tool FXA 193 Caution! If the HART communication resistor is not built into the supply unit, it is necessary to insert a communication resistor of 250 Ω into the 2-wire line.
Wiring Connect the Equipotential bonding to the external ground terminal of the transmitter. Caution! In Ex applications, the instrument must only be grounded on the sensor side. Further safety instructions are given in the separate documentation for applications in explosion hazardous areas.
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Operation – Selection and configuration in Operation menu: 1.) Change from Measured Value Display to 2.) Press to select the required ➜ First f unction (e.g. "tank shape (002)") is selected. Note! The active selection is marked by a 3.) Activate Edit mode with Selection menus: a) Select the required Parameter...
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7532 5.1.1 The operating menu is made up of two levels: • Function groups (00, 01, 03, …, 0C, 0D): The individual operating options of the instrument are split up roughly into different function groups. The function groups that are available include, e.g.: "basic setup", "safety settings", "output", "display", etc.
Operation Figure 5: 5.2.1 Liquid crystal display (LCD): Four lines with 20 characters each. Display contrast adjustable through key combination. Figure 6: Display and operating elements Layout of the display and operating elements Display – Selection list Envelope curve Display Radar Tank Gauge Headline Position indicator...
7532 5.2.2 The following table describes the symbols that appear on the liquid crystal display: Symbols Meaning Table 1: Light emitting diodes (LEDs): There is a green and a red LED besides the Liquid Crystal Display. red LED continuously on...
Operation 5.2.3 The operating elements are located inside the housing and are accessible for operation by opening the lid of the housing. Function of the keys Key(s) Table 2: Custody locking switch Access to the electronics can be prevented by means of a custody locking switch that locks the device settings;...
7532 5.3.1 The 7500 RTG can be protected in two ways against unauthorized changing of instru- ment data, numerical values or factory settings: "unlock parameter" (0A4): A value <> 100 (e.g. 99) must be entered in "unlock parameter" (0A4) in the "diagnostics"...
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Operation 5.3.2 If an attempt is made to change parameters when the instrument is locked, the user is automatically requested to unlock the instrument: "unlock parameter" (0A4): By entering the unlock parameter (on the display or via communication) 100 = for HART devices the 7500 RTG is released for operation.
7532 5.3.3 Caution! A reset sets the instrument back to the factory settings. This can lead to an impairment of the measurement. Generally, you should perform a basic setup again following a reset. A reset is only necessary: • if the instrument no longer functions •...
Operation Type of error Errors that occur during commissioning or measuring are displayed immediately on the local display. If two or more system or process errors occur, the error with the highest priority is the one shown on the display. The measuring system distinguishes between two types of error: •...
7532 Apart from local operation, you can also parameterize the measuring instrument and view measured values by means of a HART protocol. There are two options available for operation: • Operation via the universal handheld operating unit, the HART Communicator DXR 375.
Operation Radar Tank Gauge Note! Further information you may find on the CD-ROM, which is enclosed to the instrument. Menu-guided commissioning Signal analysis via envelope curve Connection options: • Service-interface with adapter FXA 193 (see page 29) • HART with Commubox FXA 191 (see page 29) Installation and Operations Manual...
7532 5.5.3 Commuwin II is an operating software with graphical support for intelligent transmitters with the communication protocols Rackbus, Rackbus RS 485, INTENSOR, HART or PROFIBUS-PA. It is compatible with the operating systems Win 3.1/3.11, Win95, Win98 and WinNT4.0. All functions of Commuwin II are supported. The configuration is made via operating matrix or graphic surface.
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Operation Radar Tank Gauge Installation and Operations Manual...
7532 Make sure that all final checks have been completed before you start up your measuring point: • Checklist “Post installation check” (see page 24). • Checklist “Post connection check” (see page 30). 6.2.1 When the instrument is switched on for the first time, the following messages appear on the display: ⇒...
Commissioning Radar Tank Gauge Basic Setup Installation and Operations Manual...
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7532 Commissioning (for bypass/stilling well) first point corrects offset further points correct linearity flange: reference point of measurement E = empty calibr. (= zero) = full calibr. (= span) settings in 005 D = distance (distance flange / product) = level...
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Commissioning To successfully commission a precise measurement to the nearest mm, it is important you carry out a history reset on first installation after mechanical installation and after the basic setup of the device (see Page 56). Only after a history reset the mounting cali- bration is carried out.
⇒ – This function is used to select the tank shape. Note! For the application of the 7532 RTG the selection "stilling well" has to be chosen in the function "tank shape" (002). Selection: • dome ceiling • horizontal cyl •...
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Commissioning Function "medium property" (003) ⇒ – This function is used to select the dielectric constant. Selection: • unknown • < 1.9 • 1.9 ... 4 • 4 ... 10 • > 10 Product class 3)Treat Ammonia NH3 as a medium of group A, i.e. always use a stilling well. DK ( 1,4 …...
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7532 Function "process cond." (004) ⇒ – This function is used to select the process conditions. Selection: • standard • calm surface • turb. surface • agitator • fast change • test:no filter For all applications that do not fit into any of the following groups.
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Commissioning Function "empty calibr." (005) ⇒ – This function is used to enter the distance from the flange (reference point of the measurement) to the minimum level (=zero). Caution! For dish bottoms or conical outlets, the zero point should be no lower than the point at which the radar beam hits the bottom of the tank.
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If mounting the 7532 RTG on stilling wells with a widening of the pipe, the inner diam- eter of the lower part of the pipe (d2 in the Fig.) must be entered. This is the part of the stilling well, where the measurement is actually performed.
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Commissioning Radar Tank Gauge Function "check distance" (051) ⇒ – This function triggers the mapping of interference echoes. To do so, the measured distance must be compared with the actual distance to the product surface. The following options are available for selection: Selection: •...
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7532 Function "range of mapping" (052) ⇒ – This function displays the suggested range of mapping. The reference point is always the reference point of the measurement (see page 46). This value can be edited by the operator. For manual mapping, the default value is: 0 m.
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Commissioning Display "dist./meas.value (008)" ⇒ – The distance measured from the reference point to the product surface and the level calculated with the aid of the empty alignment are displayed again. Check whether the values correspond to the actual level or the actual distance. The following cases can occur: •...
7532 6.5.1 ⇒ – Function "tank gauging" (030) ⇒ – Using this function, you can either enter a dip table or carry out an auto-correction. Function "auto-correction" (031) ⇒ – When measuring levels with radar systems, so-called "multipath reflections" can affect the level signal giving rise to serious measuring errors.
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Commissioning Radar Tank Gauge correction table), the maximum permissible filling speed is 100 mm level change / min. After this, the fill speed has no limitation. Function "pipe diam. corr." (032) ⇒ – For level measurement in stilling wells, radar systems require highly precise pipe inner diameter data.
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7532 Commissioning Display "custody mode" (0A9) ⇒ – This indicates the instrument calibration mode. The calibration mode (active) can be set using the hardware security lock on the electronics (see Page 34). Selection: • inactive • active pos. • active neg.
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Commissioning Dip table The dip table is used to correct the level readings of the 7500 RTG using independently taken hand dips. The dip table is used in particular to adapt the level gauge to the specific application conditions as mechanical offset and tank/stilling well design. Depending on national regulations, national inspectors will dip the tank at one to three levels during a calibration run and check the level readings.
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7532 Note! The dip table can be printed out using the ToF-Tool. Before doing this, the ToF Tool must be reconnected to the instrument in order to update the values within the ToF Tool. Note! Make your inputs into the dip table in semi-automatic mode. We advise you to leave "auto correction"...
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Commissioning manual The value pairs in the dip table can be read and written. You can enter the measured value and the dip value. –uncorrected measured value: This is the measured value supplied by the instrument, NOT corrected by the dip table.
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7532 Function "dip table handl." (036) ⇒ – Use this function to enter the dip value (level or distance) which will correct the mea- surement values. Selection: • new point • edit point • store point • delete point • return •...
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Commissioning Radar Tank Gauge delete point The currently displayed point is deleted from the table. After deletion, the previous point is displayed. If the table only consisted of one point before deletion, then the current measured variable is displayed as a value pair. return By selecting this point, you return to the function "dip table mode"...
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7532 6.5.2 After the basic setup, an evaluation of the measurement with the aid of the envelope curve ("display" (09) function group) is recommended. Function "plot settings" (09A) ⇒ – Here you can select which information is shown on the display: •...
Commissioning Radar Tank Gauge Basic Setup with the ToF Tool To carry out the basic setup with the ToF Tool operating program, proceed as follows: • Start the ToF Tool operating program and establish a connection • Select the "basic setup" function group in the navigation bar The following display appears on the screen: Basic Setup step 1/5: •...
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7532 Basic Setup step 2/5: • Enter the application parameters: –tank shape (for a description, see page 49) –medium property (for a description, see page 50) –process cond. (for a description, see page 51) Basic Setup step 3/5: If "stilling well" or "bypass" is selected in the "tank shape" function, the following display appears on the screen: •...
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Commissioning Radar Tank Gauge Note! You can also specify the pipe diameter in this display. Basic Setup step 4/5: • This step starts the tank mapping • The measured distance and the current measured value are always displayed in the header •...
7532 6.6.1 After the basic setup, an evaluation of the measurement using the envelope curve is recommended. 6.6.2 To set the parameters of user-specific applications, see the 7500 RTG "Service manual and description of instrument functions". Envelope curve with the ToF Tool...
Commissioning Radar Tank Gauge Mounting calibration with the ToF Tool To carry out the basic setup with the ToF Tool operating program, proceed as follows: • Start the ToF Tool operating program and establish a connection • Select the "mounting calibr." function group in the navigation bar The following display appears on the screen: Mounting calibration step 1/2: •...
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7532 Commissioning Mounting calibration step 2/2: • dip table mode (description see page 61) • meas. v. (description see page 62) • dip value (see page 62) • dip table handl. (description see page 63) • dip table state (description see page 61)
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Commissioning Radar Tank Gauge Installation and Operations Manual...
7532 Maintenance Maintenance The 7500 RTG measuring instrument requires no special maintenance. Exterior cleaning When cleaning the exterior of measuring devices, always use cleaning agents that do not attack the surface of the housing and the seals. Replacement After a complete 7500 RTG or electronic module has been replaced, the parameters can be downloaded into the instrument again via the communication interface.
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Maintenance Radar Tank Gauge Installation and Operations Manual...
7532 Accessories Accessories Various accessories, which can be ordered separately from Varec, are available for the 7500 RTG. Weather protection cover A Weather protection cover made of stainless steel is available for outdoor mounting (order code: 543199-0001). The shipment includes the protective cover and tension clamp.
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Accessories Radar Tank Gauge Installation and Operations Manual...
7532 Code A102 W103 A106 A110 A111 A113 A114 A115 A116 A121 W153 A155 A160 A164 A171 A231 Table 3: System error messages Description Possible cause checksum error device has been powered off general reset & new before data could be stored;...
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Troubleshooting Code A270 A272 W275 W511 A512 W601 W611 W621 E641 E651 A671 W681 Table 3: Description Possible cause custody switch switch for custody transfer undef may be defective check position inconsistency between phase and amplitude evaluation inconsistent microfactor inconsistent index mapping electronics defect inconsistency in amplification amplifier...
7532 Error Output A warning or Depending on the configuration alarm has occurred. Measured value (00) is incorrect 20 mA/100% F m/ft expected actual E m/ft 4 mA/0% No change off measured value on 20 mA/100% filling/empty- expected 4 mA/0%...
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Troubleshooting Error Output If the surface is not calm (e.g. filling, 20 mA/100% emptying, agi- actual tator run- ning), the measured value jumps sporad- ically to a higher 4 mA/0% level 20 mA/100% 4 mA/0% During filling/ emptying the measured 20 mA/100% value jumps downwards...
7532 Troubleshooting Spare parts Note! You can order spare parts directly from your Varec service organization by giving the order code and the serial number which is printed on the measuring transducer nameplate (see page 7). The corresponding spare part number also appears on each spare part.
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Troubleshooting Radar Tank Gauge 7532 RTG The customer may exchange modular assemblies in accordance with Varec instructions! Installation and Operations Manual...
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7532 Spare parts 7532 RTG Planar antenna Modification nameplate When ordering parts that are listed in the product structure (see page 8) , a check must be made as to whether the instrument description on the nameplate is still valid, e.g. for: •...
Housing T12 The complete order code must be specified when ordering the replacement housing so that the correct nameplate can be delivered, e.g. • 7532 RTG-AACWJAC1AA You must label the nameplate yourself. Caution! • It is not possible to convert a standard instrument into an Ex instrument by simply exchanging parts.
It meets the relevant requirements according to OIML R85 and API 3.1B. • The 7532 RTG with planar antenna is specifically and only suited for stilling well applications with ranges up to 38 m (124 ft).
10 equidistant points during the final test. For stilling well measurements with 7532 RTG, a NMI / PTB calibrated tape with an absolute accuracy of 0.25 mm is used. Each 7500 RTG is delivered with the PTB and NMi type approval.
7532 Inventory Control Ver- sions Operating conditions Engineering tips Environment Ambient temperature range Storage temperature Climate class Degree of protection Vibration resistance Cleaning of the antenna Electromagnetic com- patibility Process conditions Process temperature range Process temperature limits Process pressure limits...
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Technical data Design, dimensions Weight Material Process connection Operation concept Display CE approval RF approvals Overspill protection External standards and guidelines Ex approval Supplementary Documentation Mechanical construction See page 13 Approx 6 kg + weight of flange See page 8 see page 8 All process connections dispose of a gas-tight glass feed-through to prevent any gas leakage to the inside of the housing.
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Appendix basic setup tank shape dome ceiling horizontal cyl. bypass stilling well flat ceiling sphere safety settings output on alarm MIN -10% 3.6mA MAX 110% 22mA hold user specific mounting calibr. tank gauging dip table auto correct. linearisation level/ullage level CU ullage CU level DU ullage DU...
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7532 dist./meas.value check distance distance = ok dist. too small D and L dist. too big are displayed manual dist. unknown safety distance in safety dist. ackn. alarm from blocking alarm distance warning default: 0.1m self holding auto correction pipe diam. corr.
Appendix Radar Tank Gauge 11.3 Description of functions Note! A detailed description of the function groups, functions and parameters is given in the the 7500 RTG "Service manual and description of instrument functions". Installation and Operations Manual...
7532 11.4 11.4.1 The 7500 RTG is a "downward-looking" measuring system, operating based on the time-of-flight method. It measures the distance from the reference point (process connection) to the product surface. Radar impulses are emitted by an antenna, reflected off the product surface and received again by the radar system.
The different instrument versions are applied as follows: • The 7532 RTG with planar antenna is the preferred device in stilling wells ≥ 150 mm. • The 7530 RTG with horn antenna can be used in stilling wells with a diameter <150 mm.
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7532 On-site operation: • with display and operating module VU 331, • with a Personal Computer, FXA 193 and the operating software ToF Tool. The ToF Tool is a graphical operating software for instruments from Varec that operate based on the time-of-flight principle (radar, ultrasonic, guided micro-impulse). It assists with commissioning, securing data, troubleshooting, and documentation of the measuring point.
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Appendix 11.4.3 7500 RTG is a weight and measure approved level transmitter. Either the innage or the ullage can be selected as the custody transfer variable. The selected variable is the basis for the subsequent calculation of the current amount of product in a tank, along with other measured variables such as (average) temperature and pressure.
7532 11.4.5 The 7500 RTG level radar is set to custody transfer mode after commissioning using a custody locking switch (see page 36). The position of the custody locking switch is secured and sealed using the sealing pin. During custody transfer measurement, all custody transfer-relevant functions for operation are automatically locked, so that the device software can not be used, either via local operation or via digital communication settings.
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Appendix 11.4.7 The Varec Tank Side Monitor 4590 provides integrated communications for sites with multiple tanks, each with one or more sensors on the tank, such as radar, spot or average temperature, capacitive probe for water detection and/or pressure sensors. Multiple protocols out of the Tank Side Monitor guarantee connectivity to nearly any of the existing industry standard tank gauging protocols.
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