Emerson Process Management 2410 User Manual
Reference Manual
300530EN, Rev BA
September 2012
Rosemount 2410
Tank Hub
www.rosemount-tg.com
Reference Manual
NOTICE
300530EN, Rev BA
September 2012
Rosemount 2410
Rosemount 2410
Tank Hub
Read this manual before working with the product. For personal and system safety, and for
optimum product performance, make sure you thoroughly understand the contents before
installing, using, or maintaining this product.
For equipment service or support needs, contact your local Emerson Process
Management/Rosemount Tank Gauging representative.
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.
The products described in this document are NOT designed for nuclear-qualified
applications.
Using non-nuclear qualified products in applications that require nuclear-qualified hardware
or products may cause inaccurate readings.
For information on Rosemount nuclear-qualified products, contact your local Rosemount
Sales Representative.
Cover Photo: 2410_coverfoto.tif
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Reference Manual
300530EN, Rev BA
September 2012
Rosemount 2410
Table of Contents
SECTION 1
Introduction
SECTION 2
Overview
SECTION 3
Installation
1.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Manual Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Service Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Product Recycling/Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7 Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7.1 Reuse and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.7.2 Energy recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 Pipe Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.2 Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.1 Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.2 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.3 Cable Selection for Power Supply . . . . . . . . . . . . . . . 3-5
3.4.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.5 Cable Selection for the Tankbus . . . . . . . . . . . . . . . . 3-6
3.4.6 Power Budget. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.7 Tankbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.8 Typical Installations . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.4.9 Cabling for the TRL2/RS485 Bus. . . . . . . . . . . . . . . 3-21
3.4.10 Non-IS Connection. . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.4.11 Non-IS Terminal Block . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.4.12 IS Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.4.13 Intrinsically Safe Terminal Block . . . . . . . . . . . . . . . 3-29
3.4.14 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
SECTION 4
Configuration
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4.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Configuration Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Basic Configuration of a Rosemount 2410 . . . . . . . . . . . . . . . . 4-3
4.5 Advanced Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 Configuration Using TankMaster WinSetup . . . . . . . . . . . . . . . 4-4
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
4.6.1 Installation Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6.2 Advanced Configuration. . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6.3 FCU 2160 Configuration . . . . . . . . . . . . . . . . . . . . . . 4-6
SECTION 5
Operation
SECTION 6
Service and
Troubleshooting
5.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Integral Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 Start-up Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.5 LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5.1 LED Start-Up Information. . . . . . . . . . . . . . . . . . . . . . 5-6
5.5.2 Error LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6 Specifying Display Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
6.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Viewing Input and Holding Registers . . . . . . . . . . . . . 6-2
6.2.2 Editing Holding Registers. . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.3 Device Live List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.4 Configuration Backup. . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2.5 Configuration Recovery . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.6 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.7 Device Software Upgrade . . . . . . . . . . . . . . . . . . . . . 6-8
6.2.8 Write Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.2.9 Write Protection Switch . . . . . . . . . . . . . . . . . . . . . . 6-11
6.2.10 Simulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.2.11 Testing the Relays . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.2.12 Relay Output Configuration . . . . . . . . . . . . . . . . . . . 6-15
6.2.13 Loading the Default Database . . . . . . . . . . . . . . . . . 6-16
6.2.14 Logging Measurement Data . . . . . . . . . . . . . . . . . . . 6-17
6.3 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.3.1 Device Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6.3.2 Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.3.3 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
APPENDIX A
Reference Data
APPENDIX B
Product Certifications
APPENDIX C
Advanced Configuration
TOC-2
A.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.3 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
B.1 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
B.2 EU Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
B.3 Hazardous Locations Certifications . . . . . . . . . . . . . . . . . . . . . . B-3
B.3.1 Factory Mutual US Approvals . . . . . . . . . . . . . . . . . . B-3
B.3.2 Factory Mutual Canadian Approvals . . . . . . . . . . . . . B-5
B.3.3 European ATEX Directive Information . . . . . . . . . . . .B-7
B.3.4 IECEx Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B.4 Approval Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
C.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
C.2 Advanced Configuration in Winsetup . . . . . . . . . . . . . . . . . . . .C-3
C.3 Primary Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
C.4 Secondary Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Table of Contents
Reference Manual
300530EN, Rev BA
September 2012
Rosemount 2410
C.5 Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6
C.6 Hybrid Density Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . .C-10
C.6.1 Hybrid Density Configuration . . . . . . . . . . . . . . . . . .C-12
C.7 Volume Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-14
C.8 Arithmetic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-17
C.8.1 Delta Level Calculation . . . . . . . . . . . . . . . . . . . . . .C-19
Table of Contents
TOC-3
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
TOC-4
Table of Contents
Reference Manual
300530EN, Rev BA
September 2012
Section 1 Introduction
1.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
1.2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2
1.3 Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-3
1.4 Technical Documentation . . . . . . . . . . . . . . . . . . . . page 1-4
1.5 Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-5
1.6 Product Recycling/Disposal . . . . . . . . . . . . . . . . . . page 1-5
1.7 Packing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-5
Rosemount 2410
1.1 SAFETY MESSAGES
Procedures and instructions in this manual may require special precautions to
ensure the safety of the personnel performing the operations. Information that
raises potential safety issues is indicated by a warning symbol ( ). Refer to
the safety messages listed at the beginning of each section before performing
an operation preceded by this symbol.
Failure to follow these installation guidelines could result in death or serious
injury:
• Make sure only qualified personnel perform the installation.
• Use the equipment only as specified in this manual. Failure to do so may
impair the protection provided by the equipment.
Explosions could result in death or serious injury:
• Verify that the operating environment of the device is consistent with the
appropriate hazardous locations certifications.
• Before connecting a communicator in an explosive atmosphere, make sure the
instruments in the loop are installed in accordance with intrinsically safe or
non-incendive field wiring practices.
• Do not remove the gauge cover in explosive atmospheres when the circuit is
alive.
Electrical shock could cause death or serious injury.
• Use extreme caution when making contact with the leads and terminals.
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Any substitution of non-recognized parts may jeopardize safety. Repair, e.g. substitution
of components etc., may also jeopardize safety and is under no circumstances allowed.
Rosemount 2410
1.2 SYMBOLS
Reference Manual
300530EN, Rev BA
September 2012
The CE marking symbolises the conformity
of the product with the applicable European
Community Directives.
The EC-Type Examination Certificate is a
statement of a Notified Certification Body
declaring that this product meets the
Essential Health and Safety Requirements
of the ATEX directive
The FM APPROVED Mark indicates that the
equipment is approved by FM Approvals
according to applicable Approval Standards
and is applicable for installation in
hazardous locations
Protective Earth
Ground
Caution - see reference manual
Use wiring rated for maximum
ambient temperature + 15 °C
Examples:
For connections in ambient temperatures up
to 70 °C use wiring rated 85 °C minimum.
For connections in ambient temperatures up
to 60 °C use wiring rated 75 °C minimum.
For connections in ambient temperatures up
to 50 °C use wiring rated 65 °C minimum.
1-2
Section 1. Introduction
Reference Manual
300530EN, Rev BA
September 2012
Rosemount 2410
1.3 MANUAL OVERVIEW
This manual provides information on installation, configuration and
maintenance of the Rosemount 2410 Tank Hub.
Section 2: Overview
• System architecture
• Installation procedure
Section 3: Installation
• Mounting considerations
• Mechanical installation
• Electrical installation
Section 4: Configuration
• Configuration tools
• Basic configuration
• Advanced configuration
• Configuration using TankMaster
Section 5: Operation
• Display description
• Error messages
• Specifying display variables
Section 6: Service and Troubleshooting
• Troubleshooting
• Error and Warning messages
• Device status
Appendix A: Reference Data
• Specifications
• Ordering Information
Appendix B: Product Certifications
• European ATEX Directive information
• FM approvals
• Labels
•Drawings
Appendix C: Advanced Configuration
• Advanced configuration in WinSetup
• Primary and Secondary Bus
• Relay Output
• Hybrid Density Calculation
• Volume Configuration
• Arithmetic Operations
Section 1. Introduction
1-3
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
1.4 TECHNICAL DOCUMENTATION
The Raptor Tank Gauging System includes the following documentation:
• Raptor Technical Description (704010EN)
• Rosemount 5900S Reference Manual (300520EN)
• Rosemount 2410 Reference Manual (300530EN)
• Rosemount 2240S Reference Manual (300550EN)
• Rosemount 2230 Reference Manual (300560EN)
• Raptor System Configuration Manual (300510EN)
• Rosemount 5300 Product Data Sheet (00813-0100-4530)
• Rosemount 5400 Product Data Sheet (00813-0100-4026)
• Rosemount 5300 Series Reference Manual (00809-0100-4530)
• Rosemount 5400 Series Reference Manual (00809-0100-4026)
• Rosemount TankMaster WinOpi Reference Manual (303028EN)
• Rosemount Raptor Installation Drawings
1-4
Section 1. Introduction
Reference Manual
300530EN, Rev BA
September 2012
1.5 SERVICE SUPPORT For service support contact the nearest Emerson Process
Management/Rosemount Tank Gauging representative. Contact information
can be found on the web site www.rosemount-tg.com.
1.6 PRODUCT RECYCLING/DISPOSAL
Recycling of equipment and packaging should be taken into consideration
and disposed of in accordance with local and national legislation/regulations.
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.
Figure 1-1. A green label is
placed on the housing of the
2410 Tank Hub
R
A
A
T
P
E
E
S
Rosemount 2410
1.7 PACKING MATERIAL
1.7.1 Reuse and
Recycling
S
T
E
E
L
&
Rosemount Tank Radar AB is fully certified according to ISO 14001
environmental standards. By recycling the corrugated paperboard, or wooden
boxes, used for shipping our products you can contribute to take care of the
environment.
Experience has shown that wooden boxes can be used several times for
various purposes. After careful disassembly the wooden parts may be reused.
Metal waste may be converted.
C
I
T
S
A
L
P
1.7.2 Energy recovery 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.
Section 1. Introduction
1-5
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
1-6
Section 1. Introduction
Reference Manual
TankMaster
2410 Tank Hub
Modem
FCU 2160 Field
Communication Unit
Relay Outputs
Secondary Bus
(Non-IS)
Primary Bus
Tan k b u s
2240S Temperature
Transmitter
2230 Display
Group Bus
Zone 1
Zone 0
5900S Radar
Level Gauge
Secondary bus (IS)
300530EN, Rev BA
September 2012
Rosemount 2410
Section 2 Overview
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
2.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5
2.3 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-6
2.4 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . page 2-12
2.1 INTRODUCTION The Rosemount 2410 Tank Hub collects measurement data and status
information from field devices designed for the Rosemount Raptor system via
the intrinsically safe 2-wire Tankbus
transmission and power supply (see also “Tankbus” on page 3-8).
The Rosemount 2410 is designed for use in hazardous area Zone 1 (Class 1,
Division 1) and communicates with field devices in Zone 1 via the intrinsically
safe Tankbus.
The 2410 is available in two versions for single tanks or multiple tanks. The
multiple tanks version supports up to 10 tanks and 16 devices.
(1)
. The Tankbus carries both data
Figure 2-1. System integration
Measurement data and status information from one or more tanks is
distributed via the Primary Bus to a Rosemount 2160 Field Communication
Unit (FCU). Data is buffered by the 2160 and distributed to a TankMaster PC,
or a host system, whenever the FCU receives a request for data. In case no
FCU is included in the system, the 2410 can communicate directly with a host
computer.
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(1) The intrinsically safe Tankbus complies with the FISCO FOUNDATION™ fieldbus standard.
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
The Rosemount 2410 has two external buses for communication with host
systems. The Primary Bus is typically used with the TRL2 Modbus or RS-485
Modbus protocol for communication with a 2160 Field Communication Unit. If
there is no 2160 included, the Primary bus can communicate directly, or via a
modem, with the TankMaster PC.
The Secondary Bus supports various protocols such as TRL2 Modbus,
Enraf, and Varec which allows you to connect to other systems as well.
The 2410 is equipped with two solid state relays that allows controlling
external devices such as valves and pumps.
An integral display (optional) presents measurement data and device status
such as warnings and error messages. At start-up, communication settings
and optional hardware configuration is presented as well as whether it is a
Single tank or Multiple tank version of the 2410 Tank Hub.
Using the input from a Rosemount 5900S Radar Level Gauge and one or two
pressure sensors, the 2410 can be configured for online presentation of
Observed Density to a host computer. The 2410 also calculates Average
Temperature and strapping table based Volume.
Rosemount 2410 can be equipped with two relays which can be configured to
control level, temperature, and water level. The output can be connected to
an external system for alarm indication or process control. The relays are user
configurable for normally open or closed operation.
The 2410 can be configured with up to ten “virtual” relay functions. This
allows you to specify several different source variables to trigger a relay.
The Rosemount 2410 Tank Hub supports the Emerson’s Smart Wireless
solution, which is based on WirelessHART the emerging industry standard
for wireless field networks. By connecting to a Smart Wireless THUM™
Adapter, the Rosemount 2410 can be integrated in a wireless network to
provide measurement data at greatly reduced field wiring costs.
2-2
Section 2. Overview
Reference Manual
Modem
TankMaster
FCU 2160
RS232
USB / RS232
Primary bus:
TRL2 Modbus,
RS485 Modbus
Field devices
TRL2 Modbus
RS485 Modbus
Rosemount 2410
Tan kbus
DCS
Secondary bus:
Enraf and others,
HART 4-20 mA
analog output/input
Modem
USB / RS232
Tan kbus
Field devices
Rosemount 2410
Primary bus:
TRL2 Modbus,
RS485 Modbus
TankMaster
Secondary bus:
Enraf and others,
HART 4-20 mA
analog output/input
300530EN, Rev BA
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Rosemount 2410
2.1.1 Communication The Raptor system supports various communication interfaces between a
Rosemount 2410 and a TankMaster PC or other host computers as illustrated
in Figure 2-2 to Figure 2-4.
Both the Primary bus and the Secondary bus can be used for either TRL2
Modbus (standard) or RS485 Modbus communication.
On the Secondary bus you may use other communication protocols as well,
such as Enraf, Varec etc.
Figure 2-2. Typical configuration
of a Rosemount 2410 and 2160
FCU connected to PC/Host
Figure 2-3. Typical configuration
of a Rosemount 2410 connected
to PC/Host
Section 2. Overview
2-3
Rosemount 2410
Tan kbu s
Field devices
Rosemount 2410
Primary bus:
TRL2 Modbus
RS485 Modbus
TankMaster
Smart Wireless
THUM™Adapter
Smart Wireless
Gateway
Secondary bus
(1)
(Non-IS):
Enraf and others
HART 4-20 mA analog output/input
Secondary bus (IS):
Wireless HART
Reference Manual
300530EN, Rev BA
September 2012
Figure 2-4. Typical configuration
of a Rosemount 2410 with
wireless connection to Smart
Wireless Gateway and PC/Host
A THUM Adapter, connected to the Intrinsically Safe Secondary
(1)
bus, allows
wireless communication between a 2410 Tank Hub and a Smart Wireless
Gateway.
2-4
(1) The Non-IS Secondary Bus can not be used simultaneously with the IS HART 4-20 mA Sec-
ondary Bus.
Section 2. Overview
Reference Manual
2
1
3
4
576 5
56
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2.2 COMPONENTS
Figure 2-5. Rosemount 2410
components
Rosemount 2410
1. Intrinsically safe terminal compartment
2. Non-intrinsically safe terminal compartment
3. Integral display (optional)
4. Write protection switch
5. Cable entries for IS connection (two ½ - 14 NPT)
6. Cable entries for Non-IS connection (two ½ - 14 NPT, two ¾ - 14 NPT)
7. Grounding terminal
Section 2. Overview
2-5
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
2.3 SYSTEM OVERVIEW
Raptor is a state-of-the art inventory and custody transfer radar tank level
gauging system. It is developed for a wide range of applications at refineries,
tank farms and fuel depots, and fulfills the highest requirements on
performance and safety.
The field devices on the tank communicate over the intrinsically safe Tankbus.
The Tankbus is based on a standardized fieldbus, the FISCO
fieldbus, and allows integration of any device supporting that protocol. By
utilizing a bus powered 2-wire intrinsically safe fieldbus the power
consumption is minimized. The standardized fieldbus also enables integration
of other vendors’ equipment on the tank.
The Raptor product portfolio includes a wide range of components to build
small or large customized tank gauging systems. The system includes various
devices, such as radar level gauges, temperature transmitters, and pressure
transmitters for complete inventory control. Such systems are easily
expanded thanks to the modular design.
Raptor is a versatile system that is compatible with and can emulate all major
tank gauging systems. Moreover, the well-proven emulation capability
enables step-by-step modernization of a tank farm, from level gauges to
control room solutions.
It is possible to replace old mechanical or servo gauges with modern Raptor
gauges, without replacing the control system or field cabling. It is further
possible to replace old HMI/SCADA-systems and field communication
devices without replacing the old gauges.
(1)
FOUNDATION™
There is a distributed intelligence in the various system units which
continuously collect and process measurement data and status information.
When a request for information is received an immediate response is sent
with updated information.
The flexible Raptor system supports several combinations to achieve
redundancy, from control room to the different field devices. Redundant
network configuration can be achieved at all levels by doubling each unit and
using multiple control room work stations.
2-6
(1) See documents IEC 61158-2 and IEC/TS 60079-27
Section 2. Overview
Reference Manual
2230 Display
2240S Temperature
Transmitter
5900S Radar
Level Gauge
2410 Tank Hub
Tan kbus
5300 Level
Transmitter
5400 Level
Transmitter
3051S
Pressure
Transmitter
TRL2 Modbus
Group bus
2180 Field
Bus Modem
2160 Field
Communication Unit
TankMaste r PC
Plant Host Computer
2410 Tank Hub
644
644
644
644Temperature
Transmitter
TankMaster PC
Plant Host Computer
NON-HAZARDOUS AREA HAZARDOUS AREA
2240S Temperature
Transmitter
2410 Tank Hub
5900S Radar
Level Gauge
Tan kbus
Segment coupler
CUSTODY TRANSFER / INVENTORY TANK GAUGINGOPERATIONAL CONTROL
300530EN, Rev BA
September 2012
Figure 2-6. Raptor system
architecture
Rosemount 2410
Section 2. Overview
2-7
Rosemount 2410
2230
Display
2240S Temperature
Transmitter
5900S Radar
Level Gauge
2410 Tank Hub
3051S
Pressure
Transmitter
Smart Wireless
Gateway
TankMaster PC
644
644
644Temperature
Transmitter
NON-HAZARDOUS AREA HAZARDOUS AREA
2410 Tank Hub
5900S Radar
Level Gauge
Tankbus
Segment coupler
THUM
THUM
Figure 2-7. Raptor system
architecture for wireless
systems
Reference Manual
300530EN, Rev BA
September 2012
2-8
Section 2. Overview
Reference Manual
300530EN, Rev BA
September 2012
Rosemount 2410
TankMaster HMI Software
TankMaster is a powerful Windows-based Human Machine Interface (HMI) for
complete tank inventory management. It provides configuration, service,
set-up, inventory, and custody transfer functions for Raptor systems and other
supported instruments.
TankMaster is designed to be used in the Microsoft Windows XP and Vista
environment providing easy access to measurement data from your Local
Area Network (LAN).
The TankMaster WinOpi program lets the operator monitor measured tank
data. It includes alarm handling, batch reports, automatic report handling,
historical data sampling as well as inventory calculations such as Volume,
Observed Density and other parameters. A plant host computer can be
connected for further processing of data.
The TankMaster WinSetup program is a graphical user interface for
installation, configuration and service of the different devices in the Raptor
system.
Rosemount 2160 Field Communication Unit
The 2160 Field Communication Unit (FCU) is a data concentrator that
continuously polls and stores data from field devices such as radar level
gauges and temperature transmitters in a buffer memory. Whenever a request
for data is received, the FCU can immediately send data from a group of tanks
from the updated buffer memory.
Rosemount 2410 Tank Hub
The Rosemount 2410 Tank Hub acts as a power supply to the connected field
devices in the hazardous area using the intrinsically safe Tankbus.
The 2410 collects measurement data and status information from field
devices on a tank. It has two external buses for communication with various
host systems.
There are two versions of the 2410 for single tank or multiple tanks operation.
The 2410 multiple tanks version supports up to 10 tanks and 16 devices. With
the Rosemount 5300 and 5400 level transmitters the 2410 supports up to 5
tanks.
The 2410 is equipped with two relays which support configuration of up to 10
“virtual” relay functions allowing you to specify several source signals for each
relay.
The 2410 supports Intrinsically Safe (IS) and Non-Intrinsically Safe (Non-IS)
analog 4-20 mA inputs/outputs. By connecting a Smart Wireless THUM
Adapter to the IS HART 4-20 mA output, the 2410 is capable of wireless
communication with a Smart Wireless Gateway in a WirelessHART network.
Section 2. Overview
Rosemount 5900S Radar Level Gauge
The Rosemount 5900S Radar Level Gauge is an intelligent instrument for
measuring the product level inside a tank. Different antennas can be used in
order to meet the requirements of different applications. The 5900S can
measure the level of almost any product, including bitumen, crude oil, refined
products, aggressive chemicals, LPG and LNG.
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Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
The Rosemount 5900S sends microwaves towards the surface of the product
in the tank. The level is calculated based on the echo from the surface. No
part of the 5900S 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 2-in-1 version of the 5900S Radar Level Gauge has two radar modules in
the same transmitter housing allowing two independent level measurements
using one antenna.
Rosemount 5300 Guided Wave Radar
The Rosemount 5300 is a premium 2-wire guided wave radar for level
measurements on liquids, to be used in a wide range of medium accuracy
applications under various tank conditions. Rosemount 5300 includes the
5301 for liquid level measurements and the 5302 for liquid level and interface
measurements.
Rosemount 5400 Radar Level Transmitter
The Rosemount 5400 is a reliable 2-wire non-contact radar level transmitter
for liquids, to be used in a wide range of medium accuracy applications under
various tank conditions.
Rosemount 2240S Multi-Input Temperature Transmitter
The Rosemount 2240S Multi-input Temperature Transmitter can connect up
to 16 temperature spot sensors and an integrated water level sensor.
Rosemount 2230 Graphical Field Display
The Rosemount 2230 Graphical Field Display presents inventory tank
gauging data such as level, temperature, and pressure. The four softkeys
allow you to navigate through the different menus to provide all tank data,
directly in the field. The Rosemount 2230 supports up to 10 tanks. Up to three
2230 displays can be used on a single tank.
Rosemount 644 Temperature Transmitter
The Rosemount 644 is used with single spot temperature sensors.
Rosemount 3051S Pressure Transmitter
The 3051S series consists of transmitters and flanges suitable for all kinds of
applications, including crude oil tanks, pressurized tanks and tanks with /
without floating roofs.
By using a 3051S Pressure Transmitter near the bottom of the tank as a
complement to a 5900S Radar Level Gauge, the density of the product can be
calculated and presented. One or more pressure transmitters with different
scalings can be used on the same tank to measure vapor and liquid pressure.
Rosemount 2180 Field Bus Modem
2-10
The Rosemount 2180 field bus modem (FBM) is used for connecting a
TankMaster PC to the TRL2 communication bus. The 2180 is connected to
the PC using either the RS232 or the USB interface.
Section 2. Overview
Reference Manual
300530EN, Rev BA
September 2012
Rosemount 2410
Rosemount Smart Wireless Gateway and Rosemount Smart Wireless
THUM Adapter
A THUM Adapter allows wireless communication between a 2410 Tank Hub
and a Smart Wireless Gateway. The gateway is the network manager that
provides an interface between field devices and the TankMaster inventory
software or host / DCS systems.
See the Raptor Technical Description (Document no. 704010en) for more
information on the various devices and options.
Section 2. Overview
2-11
Rosemount 2410
Review Mounting Considerations.
See “Installation Considerations”
on page 3-2.
Mount the 2410.
See “Mechanical
Installation” on page 3-3.
Wire the 2410.
See “Electrical Installation” on
page 3-5.
Make sure covers
and cable/conduit
connections are tight
Power up the 2410
Configure the 2410 (Section 4: Configuration):
- tank database
- tags
- integral display
- Primary/Secondary Bus
- Relay output
- Hybrid density
Verify operation
Enable the Write Protection
switch if required
Reference Manual
300530EN, Rev BA
September 2012
2.4 INSTALLATION PROCEDURE
Follow these steps for a proper installation:
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Section 2. Overview
Reference Manual
300530EN, Rev BA
September 2012
Section 3 Installation
3.1 Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
3.2 Installation Considerations . . . . . . . . . . . . . . . . . . . page 3-2
3.3 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . page 3-3
3.4 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . page 3-5
Rosemount 2410
3.1 SAFETY MESSAGES
Procedures and instructions in this section may require special precautions to
ensure the safety of the personnel performing the operations. Information that
raises potential safety issues is indicated by a warning symbol ( ). Please
refer to the following safety messages before performing an operation
preceded by this symbol.
Failure to follow safe installation and servicing guidelines could result in death or
serious injury:
Make sure only qualified personnel perform the installation.
Use the equipment only as specified in this manual. Failure to do so may impair the
protection provided by the equipment.
Do not perform any service other than those contained in this manual unless you are
qualified.
Explosions could result in death or serious injury:
Verify that the operating environment of the device is consistent with the appropriate
hazardous locations certifications.
Before connecting a communicator in an explosive atmosphere, make sure the
instruments in the loop are installed in accordance with intrinsically safe or
non-incendive field wiring practices.
Do not remove the gauge cover in explosive atmospheres when the circuit is alive.
To prevent ignition of flammable or combustible atmospheres, disconnect power before
servicing.
www.rosemount-tg.com
High voltage that may be present on leads could cause electrical shock:
Avoid contact with leads and terminals.
Make sure the main power to the 2410 Tank Hub is off and the lines to any other
external power source are disconnected or not powered while wiring the gauge.
Rosemount 2410
Reference Manual
300530EN, Rev BA
September 2012
3.2 INSTALLATION CONSIDERATIONS
The Rosemount 2410 Tank Hub may be installed on various locations at the
plant. Mounting at the tank foot may be convenient when you would like to
have easy access to measuring data, diagnostics and other information on
the 2410 optional integral display.
The 2410 can also be mounted on the tank roof if this is the preferred location.
In case the 2410 is exposed to long periods of sunshine, a sunshade should
be used to prevent the 2410 Tank Hub from being heated to temperatures
above the maximum operating temperature.
Ensure that environmental conditions are within specified limits as listed in
Appendix A: Reference Data.
Ensure that the Rosemount 2410 is installed such that it is not exposed to
higher pressure and temperature than specified in Appendix A: Reference
Data.
The multi-tank version of the Rosemount 2410 Tank Hub is able to serve
several tanks. In that case the 2410 may be placed at a suitable location
further away from the tanks.
The 2410 is designed with two Tankbus terminals and several cable entries
which allows alternative cable routings to suit various requirements.
Do not install the Rosemount 2410 in non-intended applications, for example
environments where it may be exposed to extremely intense magnetic fields
or extreme weather conditions.
It’s a good idea to plan the installation in order ensure that all components in
the system are properly specified. The planning stage should include the
following tasks:
• make a plan of the site and specify suitable locations for the devices
• consider power budget
• specify cabling and connections (for example whether devices will be
“daisy-chained” or not)
• specify cable glands that will be needed for the various devices
• specify location of terminators on the Tankbus
• make a note of identification codes such as Unit ID/Device ID of each
device
• assign Modbus adresses for level gauges and other tank devices to be
used in the Tank Database of the 2410 and the Slave Database of the
2160 Field Communication Unit (see the Raptor System Configuration
manual, document no. 300510 for more information)
3-2
See “Electrical Installation” on page 3-5 for more information on cables and
glands.
IMPORTANT
Check the 2410 Tank Hub for any signs of damage prior to installation. Ensure
that the glass on the integral display is undamaged, and O-rings and gaskets
are in good condition.
Section 3. Installation
Reference Manual
Bracket
4 nuts and
washers
1 - 2 inches
Bracket
300530EN, Rev BA
September 2012
Rosemount 2410
3.3 MECHANICAL INSTALLATION
3.3.1 Pipe Mounting
The Rosemount 2410 is designed for mounting on a pipe stand or on a wall.
NOTE!
Ensure that the 2410 is installed to minimize vibration and mechanical shock.
1. Attach the bracket to the pipe.
2. Ensure that the 2410 is placed in a
direction so that the display is clearly
visible and wiring can be properly
connected.
3. Tighten the nuts. Use moderate torque
to ensure that the bracket does not
break.
4. Attach the 2410 to the bracket by sliding
it from the top downwards.
Section 3. Installation
5. Secure the 2410 to the bracket by
tightening the screw.
3-3
Rosemount 2410
70 mm
70 mm
94 mm
94 mm
Ø 9 mm
Screw
3.3.2 Wall Mounting
Reference Manual
300530EN, Rev BA
September 2012
1. Mount the bracket on the wall by using
four M8 screws and flat washers.
Note! Countersunk screws are not
suitable.
2. Attach the 2410 to the bracket and
tighten the screw.
3-4
Section 3. Installation
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