Emerson 308014EN, Edition 4 User Manual
Installation Manual
308014EN, Edition 4
May 2013
Tank Gauging System
www.rosemount-tg.com
Installation manual
Fourth edition
Copyright
© May 2013
Rosemount Tank Radar AB
www.rosemount-tg.com
Copyright © May 2013
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 trademarks of
Rosemount Inc.
TankRadar is a trademark of Rosemount Tank Radar AB.
HART is a trademark of HART Communication Foundation
Modbus is a trademark of Modicon.
Pentium is a trademark of Intel Corporation.
Windows NT is a trademark of Microsoft Corporation.
Viton is a trademark of Du Pont Performance Elastomers.
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.
EU Conformity
The EC declaration of conformity for all applicable European directives
for this product can be found on the Rosemount Tank Gauging website
at www.rosemount-tg.com. A hard copy may be obtained by contacting
our local sales representative.
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.
www.rosemount-tg.com
Installation Manual
308014EN, Edition 4
May 2013
Rosemount TankRadar REX
Table of Contents
Contents
Recovery of Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOC-6
Recovery of Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOC-7
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 MANUAL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
2. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 INTRINSIC SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 EXPLOSION PROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.3 EUROPEAN ATEX DIRECTIVE INFORMATION . . . . . . . . . . . . . . . . .2-3
2.3.1 Radar Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2.3.2 Radar Tank Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.3.3 Transmitter Interface Card (TIC) . . . . . . . . . . . . . . . . . . . . 2-5
2.3.4 Temperature Multiplexer Card (TMC) . . . . . . . . . . . . . . . .2-6
2.3.5 Data Acquisition Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2.3.6 Remote Display Unit 40 (RDU 40) . . . . . . . . . . . . . . . . . .2-8
3. DESCRIPTION OF 3900 REX . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 TRANSMITTER HEAD RTG 3900 REX . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.1 Transmitter Head Electronics . . . . . . . . . . . . . . . . . . . . . .3-2
3.1.2 Analog Processing Card - APC . . . . . . . . . . . . . . . . . . . .3-3
3.1.3 Transmitter Interface Card - TIC . . . . . . . . . . . . . . . . . . . .3-3
3.1.4 Temperature Multiplexer Card - TMC . . . . . . . . . . . . . . . .3-3
3.1.5 Relay Output Card - ROC . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.1.6 Field Communication Card - FCC . . . . . . . . . . . . . . . . . .3-3
3.1.7 Metrological Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3.2 ANTENNA TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
4. THE DATA ACQUISITION UNIT . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 LOCAL READOUT DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 WRITE ENABLE/INHIBIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.3 CONNECTING THE DATA ACQUISITION UNIT, DAU 2100 . . . . . . . .4-3
4.3.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.2 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.3.3 Selecting the temperature range . . . . . . . . . . . . . . . . . . .4-4
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Table of Contents
308014EN, Edition 4
May 2013
5. THE REMOTE DISPLAY UNIT RDU40. . . . . . . . . . . . . . . . 5-1
5.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.2 TWO RDU 40 CONNECTED TO THE SAME REX . . . . . . . . . . . . . . .5-4
5.2.1 Data items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
6. THE FIELD COMMUNICATION UNIT . . . . . . . . . . . . . . . . . . 6-1
6.1 FCU ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 COMMUNICATION PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.2.1 RS232 communication . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.2.2 RS 485 communication . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.3 WRITE INHIBIT/ENABLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6.4 CONNECTING THE FIELD COMMUNICATION UNIT, FCU 2160 . . .6-4
6.4.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6.4.2 Connection to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6.5 REDUNDANCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
7. BUS MODEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 FIELD BUS MODEM 2180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.1.1 DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
7.1.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7.1.3 TRL/2 Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
7.1.4 RS 232 Communication . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.1.5 USB Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
7.1.6 USB Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
7.1.7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.1.8 Communicating with TankMaster™ . . . . . . . . . . . . . . . . .7-7
7.1.9 USB Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7.1.10 RS 232 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7.1.11 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
7.2 ENRAF BUS MODEM, EBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
7.2.1 Connecting the Enraf Bus Modem . . . . . . . . . . . . . . . . . 7-11
7.2.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
8. JUNCTION BOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 INTEGRATED JUNCTION BOX, JBI . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8.1.1 Explosion Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2
8.1.3 Cable Inlets - RTG 3900 . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
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308014EN, Edition 4
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8.2 JUNCTION BOXES FOR INTRINSICALLY SAFE AND
EEX E ENVIRONMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
8.2.1 JB 140-11 for EEx i environments . . . . . . . . . . . . . . . . . .8-3
8.2.2 JB 140-15 for EEx e environments . . . . . . . . . . . . . . . . . . 8-3
8.2.3 Junction Boxes with Conduit Outlets . . . . . . . . . . . . . . . .8-4
8.3 CONNECTION OF TEMPERATURE SENSORS . . . . . . . . . . . . . . . . .8-5
8.3.1 Junction Box JBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5
8.3.2 Junction Box JB 36/42 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Rosemount TankRadar REX
Table of Contents
9. CONNECTION TO COMPUTER NETWORKS. . . . . . . . . . . . . 9-1
9.1 CONNECT TO THE FCU FOR QUICK UPDATES . . . . . . . . . . . . . . . .9-1
9.2 CONNECT TO TANKMASTER FOR INVENTORY DATA . . . . . . . . . .9-1
10. MECHANICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . 10-1
10.1 MOUNTING A HORN ANTENNA GAUGE . . . . . . . . . . . . . . . . . . . . .10-1
10.1.1 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . .10-1
10.1.2 Free Space Requirements . . . . . . . . . . . . . . . . . . . . . . .10-2
10.1.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.1.4 Installation on the tank . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
10.2 MOUNTING THE PARABOLIC ANTENNA GAUGE . . . . . . . . . . . . .10-6
10.2.1 Inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6
10.2.2 Free Space Requirements . . . . . . . . . . . . . . . . . . . . . . .10-9
10.2.3 Socket Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .10-10
10.2.4 Recommended Installation . . . . . . . . . . . . . . . . . . . . . .10-10
10.2.5 Mounting the Flange Ball model T30 . . . . . . . . . . . . . . 10-11
10.2.6 Mounting the Flange Ball model T38-W . . . . . . . . . . . .10-12
10.2.7 Mounting the Antenna . . . . . . . . . . . . . . . . . . . . . . . . .10-14
10.3 MOUNTING A STILL PIPE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . .10-20
10.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.3.2 Still Pipe Requirements . . . . . . . . . . . . . . . . . . . . . . . .10-21
10.3.3 Flange Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .10-21
10.3.4 Recommended Installation . . . . . . . . . . . . . . . . . . . . . .10-22
10.3.5 Free space requirements - RTG 3950 Fixed Version . .10-23
10.3.6 Installation of the 3950 Fixed Version on the tank . . . .10-24
10.3.7 Free space requirements - RTG 3950 Inclined Version 10-28
10.3.8 Installation of the RTG 3950 Inclined Version . . . . . . .10-30
10.4 MOUNTING A LPG/LNG GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . .10-38
10.4.1 Temperature and Pressure Measurement. . . . . . . . . . .10-38
10.4.2 Still Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-38
10.4.3 Reference Pin and Reflector . . . . . . . . . . . . . . . . . . . .10-40
10.4.4 Extension Pipe for Minimum Distance. . . . . . . . . . . . . .10-42
10.4.5 Installation on the tank. . . . . . . . . . . . . . . . . . . . . . . . . .10-43
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Table of Contents
308014EN, Edition 4
May 2013
11. ELECTRICAL INSTALLATION OF THE REX GAUGES. . . . . 11-1
11.1 CABLING FOR POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
11.2 CABLING FOR TRL/2 BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.3 RECOMMENDED CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.4 GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.5 CONNECTING THE RADAR TANK GAUGE 3900 . . . . . . . . . . . . . .11-4
11.5.1 Cable Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.5.2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7
11.5.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
11.5.4 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13
11.5.5 TRL/2 Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
11.5.6 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
11.5.7 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
11.5.8 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . .11-18
11.5.9 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
11.5.10 HART Slaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
11.5.11 DAU/RDU 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
12. SENSOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1 TEMPERATURE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1
12.2 WATER LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5
12.2.1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . .12-5
12.2.2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
13. LIST OF DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.1 MECHANICAL INSTALLATION DRAWINGS TANKRADAR REX . . .13-1
13.2 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2
13.3 FIELD BUS MODEM, FBM 2180 . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2
13.4 FIELD COMMUNICATION UNIT, FCU 2160 . . . . . . . . . . . . . . . . . . .13-3
13.5 DATA ACQUISITION UNIT, SDAU 2100 . . . . . . . . . . . . . . . . . . . . . .13-3
13.6 REMOTE DISPLAY UNIT, RDU 40 . . . . . . . . . . . . . . . . . . . . . . . . . .13-3
13.7 JUNCTION BOXES - JB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
13.8 TEMPERATURE / WLS SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
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Installation Manual
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Table of Contents
14. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
14.1 RTG 3900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1
14.1.1 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-2
14.1.2 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3
14.1.3 Analog Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3
14.1.4 External Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3
14.1.5 Temperature Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
14.2 RTG 3920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-4
14.3 RTG 3930 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-5
14.4 RTG 3950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-6
14.5 RTG 3960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-7
14.6 DATA ACQUISITION UNIT, DAU 2100 . . . . . . . . . . . . . . . . . . . . . . .14-8
14.7 REMOTE DISPLAY UNIT, RDU 40 . . . . . . . . . . . . . . . . . . . . . . . . . .14-9
14.8 FIELD COMMUNICATION UNIT, FCU 2160 . . . . . . . . . . . . . . . . . .14-10
14.9 FIELD BUS MODEM, FBM 2180 . . . . . . . . . . . . . . . . . . . . . . . . . . .14-10
14.10 ENRAF BUS MODEM, EBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-10
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-1
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Rosemount TankRadar REX
Table of Contents
Recovery of Packing Material
Rosemount Tank Radar AB is fully certified according to ISO 14000
environmental standards. By recycling the plywood boxes material used
for shipping our products you can contribute to take care of the
environment.
Reuse
Experience has shown that NEFAB ExPak packaging can be used 4-5
times.
Recycling
After careful disassembly the plywood sides may be reused. Metal waste
may be converted.
Energy recovery
Installation Manual
308014EN, Edition 4
May 2013
Products which have served their time may be divided into wood and
metal components and the wood can be used as fuel in sufficient ovens.
Due to its low moisture content (approximately 7%) this fuel has a higher
calorific value than ordinary wood fuel (moisture content approximately
20%).
When burning interior plywood the nitrogen in the adhesives may
increase emissions of nitrogen oxides to the air 3-4 times more than
when burning bark and splinter.
Note! Landfill is not a recycling option and should be avoided.
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Installation Manual
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May 2013
Recovery of Products
The label below is put on Rosemount Tank Gauging products as a
recommendation to customers if scrapping is considered.
Recycling or disposal should be done following instructions for correct
separation of materials when breaking up the units.
Rosemount TankRadar REX
Table of Contents
label_180.eps
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Rosemount TankRadar REX
Table of Contents
Installation Manual
308014EN, Edition 4
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TOC-8
Installation
308014EN, Edition 4
May 2013
1. Introduction
The Rosemount TankRadar REX System is a monitoring and control
system for tank level gauging. The system can interface various sensors,
such as temperature and pressure sensors, for complete inventory
control.
There is a distributed intelligence in the various units of the system. The
units continuously collect and process information. When a request for
information is received an immediate response is sent with updated
information. The units communicate with each other on a field bus, the
TRL/2 Bus.
No part of the equipment is in actual contact with the product in the tank
and the antenna is the only part of the gauge that is exposed to the tank
atmosphere. The Radar Tank Gauge sends microwaves towards the
surface of the product in the tank. The level is calculated based on the
echo from the surface.
Rosemount Tank Radar REX
Chapter 1 Introduction
TankRadar REX can measure the level of almost any product, including
bitumen, crude oil, refined products, aggressive chemicals, LPG and
LNG, etc. Using a suitable Tank Connection Unit, the TankRadar REX
System can gauge any type of tank.
1-1
Rosemount Tank Radar REX
Chapter 1 Introduction
Installation Manual
308014EN, Edition 4
May 2013
Plant Host
Computer
To Other
FCUs
NonHazardous
Area
Hazardous
Area
LPG/LNG
Gauge
RTG
RS-232C
FBM
To Other
Tanks
DAU
TankMaster
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TRL/2 Group Bus
FCU
TRL/2 Field Bus
Still Pipe
Gauge
RTG
Report
Printer
FCU
TRL/2 Field Bus
DAU
Parabolic Antenna Gauge
FBM
Alarm Log
Printer
To Portable
Service PC
RTG
Control
Room
Level
Group
Level
DAU
Field
Level
Temperature
Sensors
Temperature
Sensors
Figure 1-1. General configuration of a TankRadar REX sys-
tem.
All the measured data is presented to the operator by the TankMaster
WinOpi, which in its complete version contains inventory functions. A
plant host computer can be connected for further processing of data.
All Rosemount Tank Gauging supplied parts for tank top mounting weigh
less than 25 kg (55 lb.) (except for pressure flange etc. for the LPG/LNG
Gauge). This makes it possible for one man to carry the various
TankRadar parts to the tank top for installation.
Please read the Technical Description for a more detailed description of
the Rosemount TankRadar REX system.
REX_System_General.eps
1-2
Installation
308014EN, Edition 4
May 2013
The basic parts of the Rosemount TankRadar REX System are:
• The Radar Tank Gauge, RTG, is an intelligent explosion pro-
• The Data Acquisition Unit, DAU, is used for measuring tempera-
• The Field Communication Unit, FCU, acts as a gateway and
• The Field Bus Modem, FBM, is a converter between RS-232C
Rosemount Tank Radar REX
Chapter 1 Introduction
tected instrument for measuring the level of a product inside a
tank. Four different Tank Connection Units can be attached in
order to satisfy a variety of different applications.
The RTG 3900 is equipped with auxiliary inputs such as temperature sensor inputs and analog inputs. The RTG 3900 also features
two relay outputs.
ture and can, as an option, be equipped with a Local Readout Display (LCD) for presentation of measured values.
data concentrator between the Group Bus and the Field Bus. Each
FCU can have a total of 32 RTGs and 32 DAUs connected to it.
and the TRL/2 Bus. It is used for connecting a PC with TankMaster to the TRL/2 Bus.
• The TankMaster WinOpi is the operator´s interface for the REX
system. The WinOpi is used for setting up a REX system with
alarm handling, batch reports, automatic report handling, historical
data sampling and inventory calculations.
• The TankMaster WinSetup is a software for configuration, calibration and service of a REX System.
1-3
Rosemount Tank Radar REX
Chapter 1 Introduction
1.1 Manual Overview
This manual provides information about mechanical and electrical
installation of Rosemount TankRadar REX equipment. It covers the
TankRadar REX 3900 series of transmitters, and also provides
instructions for TRL/2 Data Acquisition Units, Field Communication Units
and Field Bus Modems.
Chapter 1 provides an overview of the
Rosemount TankRadar REX radar gauging system.
Chapter 2 gives a brief description of safety concepts and
European ATEX Directive information.
Chapter 3 describes the 3900 transmitter head and the cor-
responding antennas.
Chapter 4 describes the Data Acquisition Unit in the
TankRadar REX system.
Installation Manual
308014EN, Edition 4
May 2013
Chapter 5 describes the Display Unit RDU 40.
Chapter 6 describes the Field Communication Unit (FCU).
Chapter 7 describes Bus Modems used for communication
between a workstation and a TankRadar REX level gauging
system.
Chapter 8 describes various types of Junction Boxes that
can be used to connect different system units.
Chapter 9 provides information on how to connect a
TankRadar REX system to a host computer system.
Chapter 10 describes how to assemble the various gauge
types and how to mount them on a tank.
Chapter 11 describes electrical installation of the
TankRadar REX gauge system.
Chapter 12 describes installation of sub-supplier equipment
used in the TankRadar REX system.
Chapter 13 provides a list of installation drawings.
Chapter 14 provides technical data for the different REX
units.
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Installation Manual
308014EN, Edition 4
May 2013
2. Safety
Rosemount TankRadar REX equipment is often used in areas where
flammable materials are handled and where an explosive atmosphere
may be present. To protect both the plant and the personnel, precautions
must be taken to ensure that this atmosphere cannot be ignited. These
areas are called hazardous areas and equipment within these areas
must be explosion protected.
A number of different explosion protection techniques have been
developed over the years. Intrinsic safety and explosion proof (or flame
proof) safety are two techniques.
2.1 Intrinsic Safety
Intrinsic safety, IS, is based on the principle of restricting electrical
energy available in hazardous-area circuits such that any sparks or hot
surfaces, that may occur as a result of electrical faults in components,
are unable to cause ignition. Intrinsic safety is the only technique
accepted for Zone 0 hazardous areas. It is also safe for personnel and
allows equipment to be maintained without the need for a gas-free
certificate.
Rosemount Tank Radar REX
Chapter 2 Safety
For example, temperature measurement with the DAU is intrinsically
safe.
The basic principles of intrinsic safety are:
• All flammable materials are grouped according to the energy
needed to ignite them.
• Equipment located in hazardous areas are classified according to
the maximum surface temperature that it can produce and this
must be safe with the flammable gases that may be present.
• Hazardous areas are classified according to the probability that an
explosive atmosphere is present, and this dictates whether or not
a particular explosion protection technique may be used.
Note! For trouble shooting and repair work of components in or in connection
to intrinsically safe equipment, strict observance of the following rules is
necessary:
- Disconnect the power supply to the Radar Tank Gauge.
- Use a certified battery operated instrument only.
- Use Rosemount TankRadar REX original spare parts only.
Replacement with non-original spare parts may jeopardize the intrinsic
safety.
2-1
Installation Manual
Rosemount Tank Radar REX
Chapter 2 Safety
308014EN, Edition 4
2.2 Explosion Proof
Explosion proof enclosures can be used when an explosion can be
allowed inside the enclosure as long as it does not spread to the outside.
The enclosure must be strong enough to withstand the pressure and
must have narrow gaps to allow the pressure to escape without igniting
the atmosphere outside of the equipment.
Note! Any substitution to non-recognized parts may impair safety.
The explosion-proof (flame-proof) enclosure of the Transmitter Head
must not be opened while the unit is powered.
May 2013
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308014EN, Edition 4
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2.3 European ATEX Directive Information
2.3.1 Radar Unit
The REX Radar Unit has been certified to comply with Directive 94/9/EC
of the European Parliament and the Council as published in the Official
Journal of the European Communities No. L 100/1.
Figure 2-1. Certification label ATEX for the 2015 Radar Unit (used in
3900 series radar tank gauges).
Rosemount Tank Radar REX
Chapter 2 Safety
The following information is provided as part of the label of the radar unit:
• Name and address of the manufacturer
(Rosemount Tank Radar AB).
• CE Conformity Marking
• Complete model number
• The serial number of the device
• Year of construction
• Marking for explosion protection:
• Ex d IIB Gb T6 (-40 °C Ta +70 °C)
• Baseefa(2001) ATEX certificate number: Baseefa03ATEX0071X
Special Conditions for Safe Use (X):
• The Type TH2015-2019 Radar Units are not to be mounted
directly on to a tank.
• For replacement purposes the cover fastening screws are to be of
minimum grade A4-80 stainless steel.
• The permanently attached cables are to be suitably terminated
and protected against impact.
2-3
Rosemount Tank Radar REX
Chapter 2 Safety
2.3.2 Radar Tank Gauge
The 3900 Radar Tank Gauge (type TH2015-2019 Radar Unit with
antenna certified for Zone 0) has been certified to comply with Directive
94/9/EC of the European Parliament and the Council as published in the
Official Journal of the European Communities No. L 100/1.
The 3900 series of Radar Tank Gauges is intended to be mounted
directly on tank.
Figure 2-2. Certification label ATEX for the 3900 Series Radar Tank
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308014EN, Edition 4
May 2013
Gauge.
The following information is provided as part of the label of the radar tank
gauge:
• Name and address of the manufacturer
(Rosemount Tank Radar AB).
• CE Conformity Marking
• Complete model number
• The serial number of the device
• Year of construction
• Marking for explosion protection:
• Ex d IIB Ga/Gb T6 (-40 °C Ta +70 °C)
• Baseefa(2001) ATEX certificate number: Baseefa03ATEX0071X
Special Conditions for Safe Use (X):
• For replacement purposes the cover fastening screws are to be of
minimum grade A4-80 stainless steel.
2-4
• The permanently attached cables are to be suitably terminated
and protected against impact.
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308014EN, Edition 4
May 2013
2.3.3 Transmitter Interface Card (TIC)
Figure 2-3. Certification label for the Transmitter Interface Card (TIC).
The Transmitter Interface Card (TIC) is mounted within the flameproof
enclosure. It is required for intrinsically safe inputs such as 4-20 mA
current loops and local display unit.
The following information is provided as part of the label of the TIC:
Rosemount Tank Radar REX
Chapter 2 Safety
• Name and address of the manufacturer
(Rosemount Tank Radar AB)
• CE Conformity Marking:
• Year of construction
• Marking for explosion protection:
• [Ex ia] IIC (Ga) (-40 °C Ta +85 °C)
• Baseefa(2001) ATEX EC-Type Examination Certificate number:
Baseefa03ATEX0050U
Schedule of Limitations
• The Transmitter Interface Card must be housed within an enclosure which provides a degree of protection of at least IP20.
• The 0V connections must be interconnected and connected to an
I.S. earth point in accordance with EN60079-14 12.2.4., when the
component is installed within an assembly.
• The arrangements for the connections to non-hazardous area and
hazardous area external circuits must comply with the requirements of Clause 6.3 of EN 50020:2002.
Note! For electrical (I.S.) parameters refer to the appended EC-Type
Examination Certificate Baseefa03ATEX0050U.
2-5
Rosemount Tank Radar REX
Chapter 2 Safety
2.3.4 Temperature Multiplexer Card (TMC)
Figure 2-4. Certification label for the Temperature Multiplexer Card
The Temperature Multiplexer Card (TMC) is mounted within the
flameproof enclosure. It is used for connecting up to 6 temperature
sensors to the REX 3900 gauge.
The following information is provided as part of the label of the TMC:
Installation Manual
308014EN, Edition 4
May 2013
(TMC).
• Name and address of the manufacturer
(Rosemount Tank Radar AB)
• CE Conformity Marking:
• Year of construction
• Marking for explosion protection:
• [Ex ia] IIC (Ga) (-40 °C Ta +85 °C)
• Baseefa(2001) ATEX EC-Type Examination number:
Baseefa03ATEX0050U
Schedule of Limitations
• The Temperature Multiplexer Card must be housed within an
enclosure which provides a degree of protection of at least IP20.
• The 0V connections must be interconnected and connected to an
I.S. earth point in accordance with EN60079-14 12.2.4., when the
component is installed within an assembly.
• The arrangements for the connections to non-hazardous area and
hazardous area external circuits must comply with the requirements of Clause 6.3 of EN 50020:2002.
Note! For electrical (I.S.) parameters refer to the appended EC-Type
Examination Certificate Baseefa03ATEX0050U.
2-6
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May 2013
2.3.5 FF Adaptor Card (FFA)
Figure 2-5. Certification label for the FF Adaptor Card (FFA).
The FF Adaptor card (FFA) is mounted within the flameproof enclosure.
It is, in conjunction with a Fieldbus Communication Board
(BAS01ATEX1385U), used to interface to an intrinsically safe Fieldbus.
The following information is provided as part of the label of the FFA:
• Name and address of the manufacturer
Rosemount Tank Radar REX
Chapter 2 Safety
(Rosemount Tank Radar AB)
• CE Conformity Marking:
• Year of construction
• Marking for explosion protection:
• [Ex ia] IIC (Ga) (-40 °C Ta +85 °C)
• Baseefa(2001) ATEX EC-Type Examination Certificate number:
Baseefa04ATEX0119U
Schedule of Limitations
• The FF Adaptor Card must be housed within an enclosure which
provides a degree of protection of at least IP20. If the FF Adaptor
Card is mounted within a hazardous area it must be installed
within an appropriately certified flameproof enclosure.
• The arrangements for the connections to non-hazardous area and
hazardous area external circuits must comply with the requirements of Clause 6.3 of EN 50020:2002.
• The FF Adaptor Card is considered to be suitable for use within
EEx d apparatus with an Ambient Temperature range of
(-40 °C Ta +85 °C).
Note! For electrical (I.S.) parameters refer to the appended EC-Type
Examination Certificate Baseefa04ATEX0119U.
2-7
Rosemount Tank Radar REX
Chapter 2 Safety
2.3.6 Data Acquisition Unit (DAU)
Figure 2-6. Certification label ATEX for the Data Acquisition Unit.
Installation Manual
308014EN, Edition 4
May 2013
The following information is provided as part of the label of the Data
Acquisition Unit (DAU):
• Name and address of the manufacturer
(Rosemount Tank Radar AB)
• CE Conformity Marking
• Complete model number
• The serial number of the device
• Year of construction
• Marking for explosion protection:
• Ex ia IIB T4 Ga (-40 °C Ta +65 °C)
X20 Pin 6 w.r.t Pin 7 X20 Pin 5 w.r.t Pin 7 X21 (For connection of up to 14 RTDs)
Ui=14 V
Ii=334 mA
Pi=1.17 W
Li=Ci=0
Ui=6 V
Ii=60 mA
Pi=0.08 W
Li=Ci=0
U0=6 V
I0=394 mA
P0=1.25 W
Ui=1.2 V
Ii=10 mA
Pi=0.02 W
Li=0
Ci=13.5 F
2-8
• Baseefa(2001) ATEX EC-Type Examination Certificate number:
Baseefa03ATEX0044
Installation Manual
308014EN, Edition 4
May 2013
2.3.7 Remote Display Unit 40 (RDU 40)
Figure 2-7. Approval label for the Remote Display Unit RDU40.
The following information is provided as part of the label of the Remote
Display Unit 40 (RDU 40):
• Name and address of the manufacturer
• CE Conformity Marking:
Rosemount Tank Radar REX
Chapter 2 Safety
(Rosemount Tank Radar AB).
• Year of construction
• Marking for explosion protection:
• Ex ib IIC T4 Gb (-40 °C Ta +70 °C)
• Sira ATEX certificate number: Sira 00 ATEX 2062
The following instructions apply to equipment covered by certificate
number Sira 00ATEX2062:
1 The equipment may be used with flammable gases and vapours
with apparatus groups IIC, IIB and IIA and with temperature
classes T1, T2, T3 and T4.
2 The equipment is only certified for use in ambient temperatures in
the range -40 °C to +70 °C and should not be used outside this
range.
3 Installation shall be carried out in accordance with the applicable
code of practice.
4 Repair of this equipment shall be carried out in accordance with
the applicable code of practice.
5 Certification marking as detailed in drawing number 9150 074-
980.
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Rosemount Tank Radar REX
Chapter 2 Safety
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3. Description of 3900 REX
3.1 Transmitter Head RTG 3900 REX
Depending on the type of tank connection unit that the transmitter head
is mounted on, there are four types of Radar Tank Gauges. The
transmitter head contains all the electronics for signal processing,
communication and connection of external sensors. The RTG 3900
transmitter head is used on all the gauge types 3920 - 3960.
Rosemount Tank Radar REX
Chapter 3 Description of 3900 REX
RTG 3920 RTG 3930 RTG 3950 RTG 3960
The Horn Antenna
Gauge for fixed roof
installation without still
pipe.
The Parabolic
Antenna Gauge for
demanding environments without still pipe.
The Still Pipe Gauge
for measuring in still
pipes.
The LPG/LNG Gauge
for liquid gas, LPG and
LNG.
3900_TH.eps
Figure 3-1. The RTG 3900 gauge can use different antennas.
3-1
Rosemount Tank Radar REX
Chapter 3 Description of 3900 REX
3.1.1 Transmitter Head Electronics
The electronics is mounted in an exchangable unit in the explosion proof
Transmitter Head. A high measurement accuracy is achieved by using
digital reference circuitry, and by controlling the internal temperature by
an internal heater.
The 3900 transmitter head can be used on all types of TRL/2 antennas.
A metrological seal is available to prevent unauthorized changes of
database settings.
Some of the electronic cards shown below are optional and may not be
installed in your transmitter.
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308014EN, Edition 4
May 2013
Transmitter Rectifier Card
3
1
2
4
1. X12. Intrinsically safe connec-
2. X11. Non-intrinsically safe con-
3. Electronic unit.
4. Ground connection.
Field Communication Card
Signal Processing Card
Analog Processing Card
Transmitter Interface Card
Temperature Multiplexing
Motherboard
tion for auxiliary inputs such as
Slave DAU/RDU, temperature
sensors and analog inputs.
nection for power, communication and relays.
REX3900_TH_Electronics.eps
3-2
Figure 3-2. RTG 3900 transmitter head electronics.
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308014EN, Edition 4
May 2013
3.1.2 Analog Processing Card - APC
The APC is used for filtering and multiplexing of analog input signals. By
keeping the analog circuitry on a separate card a high Signal to Noise
Ratio is achieved.
3.1.3 Transmitter Interface Card - TIC
The Transmitter Interface Card (TIC) is required for intrinsically safe
auxiliary inputs. The TIC includes:
• Two supply zener barriers and two return zener barriers for 4-20
• One supply zener barrier for a Slave Data Acquisition Unit or a
• Signal/supply connection for optional Temperature Multiplexer
Rosemount Tank Radar REX
Chapter 3 Description of 3900 REX
mA current loops.
Remote Display Unit.
Card (TMC).
3.1.4 Temperature Multiplexer Card - TMC
The Temperature Multiplexer Card (TMC) is used to connect up to 6
temperature sensors. Both spot and average sensors are supported.
3.1.5 Relay Output Card - ROC
The Relay Output Card (ROC) contains two relays. It allows controlling
external devices such as valves, pumps, heating coils, overfill protection
according to TÜV etc.
3.1.6 Field Communication Card - FCC
The Field Communication Card (FCC) handles communication with
external devices. There are different versions of the FCC card allowing
you to use various types of communication protocols and even emulate
other types of gauges.
3-3
Rosemount Tank Radar REX
Chapter 3 Description of 3900 REX
3.1.7 Metrological Seal
A switch on the FCC board can be used to prevent unauthorized
changes in the RTG database. The switch can be sealed in the writeinhibit position by using a special plastic cover.
Internal switch
Metrological Seal
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308014EN, Edition 4
May 2013
TH_Top.eps
Figure 3-3. RTG 3900 transmitter head with metrological seal.
External switch
REX can also be equipped with an external metrological seal. It consists
of a rod which is connected to a write protection switch inside the
transmitter head. The rod can be sealed.
Write enable
Write inhibit
WriteProtect.eps
3-4
Figure 3-4. RTG 3900 transmitter head with metrological seal.
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