Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
Commissioning Manual
www.rosemount-tg.com
Commissioning manual
Second edition
Revision B
Copyright
© June 2008
Rosemount Tank Radar AB
www.rosemount-tg.com
Copyright © June 2008
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 registered trademarks of
Rosemount Inc.
TankRadar is a registered trademark of Rosemount Tank Radar AB.
HART is a registered trademark of HART Communication Foundation
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.
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
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
Rosemount TankRadar Rex
Table of Contents
Contents
1. CHECKS AND ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 TANK INTERIOR CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 SYSTEM COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 FCU CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5.1 FCU information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5.3 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.4 Field bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.5 Group bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.6 FBM 2180 CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.1 FBM information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6.3 Field bus check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6.4 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 COMMUNICATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.8 RTG 3900 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.8.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8.2 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.8.3 Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
1.9 RTG 3920 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.9.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.9.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.9.3 Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.9.4 Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . .1-8
1.10 RTG 3930 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.10.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.10.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
1.10.3 Tank measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.10.4 Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . 1-11
TOC-1
Rosemount TankRadar Rex
Table of Contents
1.11 RTG 3950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.11.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.11.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.11.3 Still-Pipe Requirements . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1.11.4 Free space requirements . . . . . . . . . . . . . . . . . . . . . . . .1-13
1.12 RTG 3960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
1.12.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.12.2 Visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1.12.3 Still-Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
1.12.4 Verification Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
1.13 REX CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
1.13.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.13.2 Tank Distances and RTG Geometry . . . . . . . . . . . . . . . . 1-19
1.13.3 Rex configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20
1.13.4 Input Register parameters . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.13.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
1.14 DATA ACQUISITION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
1.14.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14.2 Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14.3 Cable and Junction box . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14.4 Electrical check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14.5 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.14.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
1.15 DAU CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.15.1 Tank Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.15.2 Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.15.3 Current inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.15.4 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.16 OPERATOR SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
1.16.1 TankMaster WinOpi . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
1.16.2 Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-1
TOC-2
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
Chapter 1 Checks and Adjustments
1. Checks and Adjustments
1.1 General
Commissioning a Rex system aims at checking the mechanical and
electrical installations.
It includes calibrations and adjustments in order to achieve high
accuracy and reliability. The communication between various TRL/2 and
Rex units is checked, and necessary backups of database files etc. are
created. It also includes checking that the installations are done
according to safety regulations.
This manual provides brief descriptions of most of the items in the Check
List for Rosemount TankRadar Rex. The checklist is used as a guide
when commissioning a Rex system. When you need more information
on a certain item in the check list, read the corresponding section in this
chapter for further information.
Rosemount TankRadar Rex
Note! Before commissioning a Rex system, always read the Rex Installation
Manual (Document No. 308014), Rex Special Safety Instruction
(Document No. 308016), and Rex Safety Manual (SIL2; Document No.
308020).
1.2 Preparations
Check that the equipment is undamaged and that it corresponds to the
specifications. Note the following information:
• Delivery no. the system number provided by the project department at Emerson Process Management/Rosemount Tank
Gauging.
• Name and location of plant.
• Service agency: the name of the local agency responsible for the
installation.
• Engineer responsible for the commissioning, and the date when
commissioning was concluded.
• Note the tank distances needed for installation and configuration
of the Rosemount Tank Radar Rex system. See “Tank measurements” on page 1-8 for illustrations of the different tank distances.
• Note the addresses to be used for the communication between the
connected devices (RTG, DAU, FCU) and TankMaster.
1-1
Rosemount TankRadar Rex
Chapter 1 Checks and Adjustments
• Check that the correct hardware parts are installed.
• Make sure that you bring appropriate tools and instruments.
• Install TankMaster.
1.3 Tank Interior Conditions
Look for objects which may produce disturbing echoes like girders,
heating coils or agitators. Disturbing objects can severely affect the
accuracy of the measurements.
1.4 System Composition
Enter the following information about the system:
• Number of tanks.
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
• System Master. There may be several units acting as master at
different occasions. The system is supervised by TankMaster
(WinOpi). A portable service PC may temporarily be connected to
an FCU when system service is required (WinSetup). A host computer can be connected to an FCU or to the TankMaster PC in
order to further process measured data (level, temperature, pressure etc.).
• The number of FCUs, FBMs, RTGs and DAUs.
1.5 FCU checklist
1.5.1 FCU information
Note the name, Unit ID
and address of each FCU.
This will facilitate the
configuration of the Rex
system. Check that the
Unit ID placed at the cover
of the FCU box and on the
FCU motherboard match.
Note the address which
will be used for the
different FCUs.
1.5.2 Visual check
Figure 1-1. Position of Unit ID on FCU
cover.
1-2
• The FCU is not intrinsically safe. It must therefore be installed in a
nonhazardous area.
• Weather protection: make a note whether the FCU is placed in a
control room or another weather protected location.
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
1.5.3 Electrical check
• Power supply. Check that the switch inside the FCU box is set to
the correct value. 230 V is the default value. If 115 V is used, the
box on the nameplate "Mark box if re-wired for 115 VAC" shall be
marked.
• Grounding: if there is no protective ground in the mains supply
cable, the FCU should be externally grounded via the ground connection at the outside of the FCU box.
1.5.4 Field bus check
Rosemount TankRadar Rex
Chapter 1 Checks and Adjustments
• Use a shielded twisted pair cable with an area of at least 0.50 mm
for the TRL/2 bus.
• Shielded cables are required in order to avoid crosstalk if the
cables run alongside and also to avoid other disturbances. The
field bus shield should be connected to ground at the FCU only.
Contact Emerson Process Management/Rosemount Tank
Gauging for further instructions.
• Note the distance if there are two fieldbuses running in parallel.
1.5.5 Group bus check
• Note the number of group buses that are used. The FCU can be
configured with two, three or four group bus ports.
• Note whether the group bus communicates via the RS-232C or
the TRL/2 bus interface. By replacing the FCM board with an FCI
board, RS-485 communication can also be used.
1.5.6 Software
• Note if redundant FCUs are used.
• Note the FCU program version.
2
To view the FCU program version:
1 Select the FCU icon in the TankMaster WinSetup workspace.
2 Click the right mouse button and choose the Properties option.
3 Select the Communication tab.
1-3
Rosemount TankRadar Rex
Chapter 1 Checks and Adjustments
1.6 FBM 2180 checklist
1.6.1 FBM information
• Note the name and version of each FBM.
1.6.2 Visual check
• Note if the FBM is installed outdoors or in the control room.
• Check if there is anything in the surroundings which may disturb
the communication such as electromagnetic fields like radiators,
big motors and transformers.
1.6.3 Field bus check
• Check that the TRL/2 bus is connected to socket 2 and 3. Use
twisted and shielded single pair cable with minimum cross sec-
tional area 0.50 mm
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
2
.
Cable dimension Maximum length
AWG 20 (0.50 mm
AWG 18 (0.75 mm
Table 1-1: Recommended wiring length
• Connect the shield to terminal 1 or 4.
• Connect ground cable to terminal 1 or 4.
Figure 1-2 FBM 2180
1.6.4 Power supply
TRL/2 bus
2
)
2
)
3000 m
4000 m
1-4
• Do not use external power supply when the modem is connected
to the USB port. The USB interface itself supports power to the
FBM 2180 modem.
Commissioning Manual
308011En, Ed.2/Rev.B
June 2008
1.7 Communication overview
Make a simple drawing showing all tanks and installed units, see Figure
1-3. Include cable lengths. Describe the composition of tanks, Radar
Tank Gauges, Data Acquisition Units, Field Communication Units, Field
Bus Modems and system master. Try to provide as much detail as
possible. A complete view of the system including TankMaster WinOpi
and host computers should be provided, including information on which
Rex units the host computer is connected to.
Rosemount TankRadar Rex
Chapter 1 Checks and Adjustments
TankMaster
WinOpi
Plant host
computer
Portable
Service PC
Field bus
FCU
FBM
Group Bus
(TRL/2 Bus)
FCU
Field bus
RTG/
DAU
Tank 1 Tank 2 Tank 3
RTG/
DAU
Tank Group 1
RTG/
DAU
RTG/
DAU
Tank 4 Tank 5
RTG/
DAU
RTG/
DAU
Tank 6
Tank Group 2
Figure 1-3 Example of System Composition drawing.
1-5
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