G3
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Service
Manual
™
Third edition
Copyright © June 1997
Saab Marine Electronics AB
Service Manual
The contents, descriptions and specifications within this
manual are subject to change without notice. Saab Marine
Electronics AB accepts no responsibility for any errors that
may appear in this manual.
As each Saab TankRadar system is specially designed for
each delivery, the contents and illustrations in this manual
may differ from your system.
Guide to this manual
If there is a problem with you Saab TankRadar system, start
by reading the chapter 9 for information on how to find the
problem and how to fix it.
If you are not familiar with the Saab TankRadar system, read
chapter 1 to get an overview. If you need more information,
read the Technical Description, included in the "As-built
drawings and user's manual"-binder.
Use the index at the back of the manual to find the page with
the information you are looking for.
Complete service information
If your Saab TankRadar G3 is complemented with Saab
TankRadar MaC cargo control system including the Substation for handling of control input and output signals, there is
an additional Service Manual for these parts.
In this case the service information is divided in two parts:
• Consult this Saab TankRadar G3 Service Manual for
information on the Saab TankRadar G3.
• Consult the Service Manual for Saab TankRadar MaC
for information related to the control system's Substa-
tion and Redundancy Switch Box.
Information on how to operate the Saab TankRadar system
If you need information about the operation of the Work
Station or the Backup Display of the Level Unit, read the
Operating Manual included in the "As-built drawings and
user's manual"-binder.
Information about technical data of the Saab TankRadar system
If you need to look at the technical specifications of the Saab
TankRadar system, please read the Technical Description
included in the "As-built drawings and user's manual"binder.
2
Third edition, June 1997
Service Manual
Overview of Contents
Guide to this manual ............................................................................... 2
1 General Description of Saab TankRadar ...................................... 10
2 General Information....................................................................... 13
3 Work Station................................................................................... 15
4 I/O Box ............................................................................................. 55
5 Level Unit ........................................................................................ 59
6 Transmitters.................................................................................... 74
7 Temperature Sensors (Option) ..................................................... 83
8 Tank Display Unit (Option)............................................................ 86
9 Fault Finding on the Saab TankRadar System ............................. 88
10 Spare Parts .................................................................................... 103
11 Recycling of Saab TankRadar ....................................................... 104
12 Saab Marine Service Agents ........................................................ 105
Index ...................................................................................................... 107
Third edition, June 1997
3
Service Manual
Complete Table of Contents
Guide to this manual ............................................................................... 2
Complete service information ........................................................................... 2
Information on how to operate the Saab TankRadar system.......................... 2
Information about technical data of the Saab TankRadar system .................. 2
Abbreviations and Denominations:.................................................................... 9
1 General Description of Saab TankRadar ...................................... 10
1.1 Radar Principle...................................................................................... 12
2 General Information....................................................................... 13
2.1 Safety ..................................................................................................... 13
3 Work Station................................................................................... 15
3.1 Description of the Work Station’s Cabinet ........................................ 16
3.2 Replacing the Work Station’s Hard Disk ............................................ 16
3.3 Replacing a Work Station .................................................................... 16
3.4 Replacing a Board in the Work Station .............................................. 17
3.5 Screen Settings of the Work Station Monitor ................................... 18
3.6 Loading Software to a Work Station .................................................. 18
3.6.1 Install Program on Hard Disk of Work Station........................... 18
3.6.2 Install Database and Pictures on Hard Disk of Work Station ... 18
3.7 The Service Windows of the Work Station Software ....................... 19
3.8 Level Unit – Version Summary and Database Status........................ 20
3.9 Level Unit – Transmitter Data............................................................. 20
3.10 Level Unit – Temperature Data ........................................................... 26
3.11 Level Unit – IG Pressure Data............................................................. 28
3.12 Level Unit – Extra Sensor Data........................................................... 29
3.13 Level Unit – Trim/List Data .................................................................. 30
3.14 Level Unit – LCM 1 and 2 Status......................................................... 31
3.15 Level Unit – LCI Status ........................................................................ 33
3.16 Level Unit – LI Status ........................................................................... 35
3.17 Level Unit – Backup and Local Display ............................................... 36
3.18 Level Unit – LCI Com Ports ................................................................ 38
3.19 Level Unit – Relays................................................................................ 39
3.20 Level Unit – Work Station Communication ...................................... 40
3.21 Level Unit – Any Register..................................................................... 41
3.22 Level Unit – LCI, LCM Version............................................................. 43
3.23 Level Unit – Load Program.................................................................. 44
3.24 Level Unit – Up/Download Database .................................................. 45
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Third edition, June 1997
Service Manual
3.25 Level Unit – TX Service ....................................................................... 46
3.26 Level Unit – Scan Tank ......................................................................... 47
3.27 Level Unit – Restart LCI, LCM ............................................................ 47
3.28 Level Unit – IG Press Zero Adjust ....................................................... 48
3.29 Disconnect LU ...................................................................................... 49
3.30 The Communication-Window ............................................................ 49
3.31 The I/O-Window ................................................................................... 50
3.32 Install/Backup-Window ........................................................................ 51
3.32.1 Backup Copies of the Database and Pictures .............................. 51
3.32.2 Install Database and Pictures ........................................................ 52
3.32.3 Installing New Program to the Work Station .............................. 52
3.32.4 Saving a Log-file to a Diskette....................................................... 52
3.33 Service Log-Window ............................................................................ 53
3.34 Process Debugger, Interface Editor, PictCopy, Shell ......................... 54
4 I/O Box ............................................................................................. 55
4.1 The Motherboard of the I/O Box ........................................................ 56
4.1.1 Watch Dog LED ............................................................................... 56
4.1.2 Communication LEDs .................................................................... 57
4.1.3 Power LED ....................................................................................... 57
4.1.4 Relays ................................................................................................ 57
4.1.5 Power Setting ................................................................................... 57
4.2 RS-232 Interface Board ........................................................................ 57
4.3 RS 485 Interface Board ........................................................................ 57
4.4 SIOX Interface Board........................................................................... 58
4.5 PRS Interface Board ............................................................................. 58
5 Level Unit ........................................................................................ 59
5.1 Description of the Level Unit .............................................................. 59
5.2 Information Flow within the Level Unit ............................................. 60
5.3 Restarting the Level Unit..................................................................... 61
5.4 Description of the Calculation Unit.................................................... 61
5.5 Signal Board, LCS ................................................................................. 62
5.5.1 Replacing a LCS............................................................................... 62
5.6 Processor Memory Board, LCM .......................................................... 62
5.6.1 Replacing the LCM ......................................................................... 62
5.7 Interface Board, LCI ............................................................................. 63
5.8 Trim/List Unit, LT ................................................................................. 65
Third edition, June 1997
5.7.1 Troubleshooting the LCI................................................................. 63
5.7.2 Replacing the LCI ............................................................................ 64
5.8.1 Replacing the Trim/List Unit ........................................................ 65
5.8.2 Adjusting the Trim/List Unit ........................................................ 66
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Service Manual
5.9 Backup Display, LCB ............................................................................. 68
5.9.1 Replacing the Backup Display ...................................................... 68
5.9.2 Description of the Service Frames ................................................ 68
5.9.3 Unit Frame ....................................................................................... 68
5.9.4 Local Display Frame ....................................................................... 69
5.9.5 Register Frame ................................................................................. 69
5.9.6 FiltDist Frame .................................................................................. 69
5.9.7 Amplitude Frame ............................................................................ 70
5.10 Transmitter Interface, LI ...................................................................... 70
5.10.1 Cabling.............................................................................................. 70
5.10.2 Configuration of the Transmitter Interfaces ................................ 70
5.10.3 Power supply to the Transmitter Interface .................................. 71
5.10.4 Ground Failure Indication ............................................................. 71
5.10.5 Addressing the Transmitter Interface........................................... 71
5.10.6 The Analog/Digital/Power Board (LIA)..................................... 71
5.10.7 The Zener Barrier Board (LIZ)....................................................... 72
5.10.8 Removing a Transmitter Interface (LI) ......................................... 72
5.10.9 Replacing a LIZ or a LIA ................................................................ 72
5.10.10 Replacing a Transmitter Interface (LI).......................................... 73
5.11 Power Block........................................................................................... 73
5.11.1 Fuses in the Power Block ............................................................... 73
5.11.2 Replacing the Power Block ............................................................ 73
6 Transmitters.................................................................................... 74
6.1 Replacing an Electronic Box ................................................................ 75
6.2 Transmitter Test Cable ......................................................................... 77
6.3 Cleaning the Antenna ........................................................................... 78
6.3.1 Cleaning the Parabolic Antenna ................................................... 78
6.3.2 Brush cleaning the Parabolic Antenna ......................................... 78
6.3.3 Cleaning by Hand ........................................................................... 79
6.3.4 Cleaning the Cone Antenna........................................................... 79
6.4 Inert Gas Pressure Sensor (Option) ................................................... 80
6.4.1 Cleaning the Inert Gas Pressure Sensor ....................................... 81
6.4.2 Replacing the Inert Gas Pressure Sensor ..................................... 81
6.4.3 Zero Pressure Calibration of IG Pressure Sensor........................ 81
6.5 Dismounting of Antenna Feeder of the Parabolic Antenna ............. 82
6.5.1 Disassembly ..................................................................................... 82
6.5.2 Reassembly:...................................................................................... 82
7 Temperature Sensors (Option)..................................................... 83
7.1 Checking a Temperature Sensor ......................................................... 83
7.2 Replacing a Faulty Temperature Sensor ............................................. 85
8 Tank Display Unit (Option)............................................................ 86
8.1 Replacing a Tank Display Unit.............................................................. 86
8.2 Checking the Tank Display Power Supply Unit .................................. 87
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Third edition, June 1997
Service Manual
9 Fault Finding on the Saab TankRadar System ............................. 88
Abbreviations used in the fault finding chart: .......................................... 88
9.1 SysFail and Warning Messages Shown on the Work Station ........... 88
9.1.1 SysFail message: Level Unit SysFail. ....................................... 88
9.1.2 SysFail message: Level Unit Communication Failed. ........... 88
9.1.3 SysFail message: Level Unit Power Failure. ........................... 89
9.1.4 SysFail message: Level Unit LI Communication Failed. ...... 89
9.1.5 SysFail message: I/O Box Communication Failed. ............... 89
9.1.6 Warning message: Level Unit Ground Failure....................... 89
9.1.7 Warning message: Level Unit Memory Failure. .................... 90
9.1.8 Warning message: Level Unit Restarted. ................................ 90
9.1.9 Warning message: Master Communication Failed. ............... 90
9.1.10 Warning message: LevelDatic Communication Failed. ........ 90
9.1.11 Warning message: SIOX Communication Failed. .................. 91
9.1.12 Warning message: PRS Communication Failed. .................... 91
9.2 Other Messages Shown on the Work Station .................................... 91
9.2.1 Message: PROCESS DATABASE NOT RUNNING - Alarm
handling is off and pictures are not updated. Please wait
until system restart..................................................................... 91
9.2.2 Message: NO CONTACT WITH MASTER WORKSTATION Network Error or Master Work Station not running. Please
wait until connection established............................................. 91
9.3 Channels with status CFAIL, ERROR or INVAL................................ 92
9.3.1 CFAIL status on one Transmitter.............................................. 92
9.3.2 CFAIL status on five Transmitters ............................................ 92
9.3.3 ERROR status on one Transmitter, but not CFAIL status ..... 92
9.3.4 Warning “Clean antenna on tank XXX” .................................. 93
9.3.5 All warnings associated with one tank shown on Work Sta-
tion ................................................................................................ 93
9.3.6 ERROR status on one temperature sensor.............................. 93
9.3.7 INVAL status on average temperature.................................... 93
9.3.8 ERROR status on one IG pressure sensor ............................... 93
9.4 Work Station ......................................................................................... 93
9.4.1 Work Station screen blank. ........................................................ 93
9.4.2 Work Station monitor image located incorrectly, distorted or
discolored. ................................................................................... 94
9.4.3 No new windows can be opened on the Work Station or
Work Station cannot be started................................................. 94
9.4.4 Light Pen is not functioning...................................................... 94
9.5 Level Unit .............................................................................................. 94
9.5.1 Backup Display is blank. ........................................................... 94
9.5.2 No response when pressing the keys on the Backup Display’s
keyboard. ..................................................................................... 94
9.5.3 Watch Dog LED on LCI board is on (the lowest LED).......... 94
9.5.4 Backup Display shows “No flash program” .......................... 94
Third edition, June 1997
7
Service Manual
9.6 Transmitters .......................................................................................... 95
9.6.1 Ullage indication not updated close to empty tank. ............. 95
9.7 Local Display ......................................................................................... 95
9.7.1 Local Display blank.................................................................... 95
9.8 Temperature Measurement................................................................. 95
9.8.1 Incorrect temperature values on one tank .............................. 95
9.9 Inert Gas Pressure Measurement ....................................................... 95
9.9.1 Incorrect reading of the IG pressure ........................................ 95
9.9.2 Indicated inert gas pressure always the same........................ 96
9.10 Tank Display Unit.................................................................................. 96
9.10.1 Display on TDU not working. .................................................. 96
9.11 Portable Readout System: ................................................................... 96
9.11.1 Indication of communication error (CERR) on PRU. ............ 96
9.11.2 No voice communication between walkie-talkie and base
9.11.3 No display on PRU..................................................................... 96
9.12 Draft measurement.............................................................................. 97
9.12.1 Draft measurement incorrect .................................................... 97
radio (PRS). .................................................................................. 96
9.13 Load Calculator .................................................................................... 97
9.13.1 Values displayed on TankRadar and load calculator differ.. 97
9.14 Finding Cause of Ground Failure Warning......................................... 98
9.14.1 Ground Failure – Transmitter Interface ....................................... 98
9.14.2 Ground Failure – Transmitter Cable............................................. 98
9.14.3 Ground Failure – Temperature Sensors ....................................... 98
9.14.4 Ground Failure – IG Pressure Sensor ........................................... 99
9.14.5 Ground Failure – Extra Temperature Sensors ............................. 99
9.14.6 Ground Failure – Local Display .................................................... 99
9.14.7 Ground Failure – Wire Terminals ............................................... 100
9.14.8 Checking a Cable for Ground Failure ........................................ 100
9.14.9 Checking a Wire Terminal for Ground Failure ......................... 100
9.15 Comparing Ullages ............................................................................. 101
10 Spare Parts .................................................................................... 103
10.1 Standard Spare Parts Set, 9150065-981 ........................................... 103
10.2 Extended Spare Parts Set, 9150065-982........................................... 103
10.3 Complete Spare Parts Set, 9150065-983.......................................... 103
11 Recycling of Saab TankRadar ....................................................... 104
12 Saab Marine Service Agents ........................................................ 105
Index ...................................................................................................... 107
8
Third edition, June 1997
Abbreviations and Denominations:
The following abbreviations are used in this manual:
LC - Calculation Unit
LCB - Backup Display
LCI - Interface Board
LCM - Processor Memory Board
LCP - Calculation Unit Power Supply
LCS - Signal Board
LI - Transmitter Interface
LIA - Analog/Digital/Power Board
LIZ - Zener Barrier Board
LP - Power Block
LU - Level Unit
TX - Transmitter
WS - Work Station.
Service Manual
Third edition, June 1997
9
Service Manual
1 General Description of Saab TankRadar
Saab TankRadar is made up mainly by the following parts:
• Transmitters
• Level Unit
• Work Station.
These units are shown in figure 1-1 below.
All Saab TankRadar Marine transmitters are intrinsically
safe, providing a number of benefits for the operator. There is
a high degree of safety built into the system. Since its impossible for electrical faults to cause an igniting spark, the equipment can be serviced at any time, even though the ship is in
operation.
Portable
Readout
Unit
Electro
pneumatic
level gauging
system
(ballast etc.)
Portable
Readout
System
Base Radio
Ship host
computer
system
Overfill and
high level
alarm
system
98%
98%
98%
Pt 1
Ct 1
St 1
95%
95%
95%
98%
98%
98%
Pt 2
Ct 2
St 2
95%
95%
95%
98%
98%
98%
Pt 3
Ct 3
St 3
95%
95%
95%
ON OFF
ALARM
LAMP
ACCEPT
HOLD
TEST
HORN FLASH
Cone Antenna
Transmitter
with IG Pressure
Sensor
Analog
in/outputs
Digital
in/outputs
Temperature
Sensors
%
SAAB
100
*
80
HH
H
60
H
L
40
L
LL
R
20
COMMON
ALARM
0
m
Load
calculator
Tank
Display
Units
%
%
%
SAAB
SAAB
SAAB
100
100
100
*
*
*
80
80
80
HH
HH
HH
H
H
H
60
60
60
H
H
H
L
L
L
40
40
40
L
L
L
LL
LL
LL
R
R
R
20
20
20
COMMON
COMMON
COMMON
ALARM
ALARM
ALARM
0
0
0
m
m
m
Parabolic Antenna
Transmitter with
IG Pressure
Sensor
Work
Exit all
Help
Wed Aug 24 20:05:30 1994
Saab TankRadar
Window Overview Setup Group Trend Alarm
Cargo System Fore
ExitBack
CT1
CT2
CT3
CT4
Ullage
Ullage
Station
Ullage
Ullage
1.559 m
8.502 m
5.630 m
1.956 m
0.00 m/h
0.00 m/h
0.00 m/h
0.00 m/h
T=19.1
T=19.1
T=19.1
T=19.1
T=18.7
T=18.7
T=18.7
T=18.7
T=18.6
P
T=18.6
P
P
P
T=18.6
T=18.6
T.avg
T.avg
T.avg
T.avg
18.8 C
18.8 C
18.8 C
18.8 C
LC1
LC3
LC5
LC7
LC2
LC4
LC6
LC8
23 bar
20 bar
24 bar
26 bar
BuzzerStop
Accept
2...more
m
(2,000)
1,837
CT 6 Ullage
Hi.Hi
Alarm
I/O
Box
Level
Unit
7890
456
M
123
ENT CLE
Printer
To Saab TankRadar MaC
Local
Display
Temperature
Sensors
Help
Wed Aug 24 20:05:30 1994
Saab TankRadar
Window Overview Setup Group Trend Alarm
Cargo System Fore
CT1
CT2
CT3
CT4
Ullage
Ullage
Ullage
Ullage
1.559 m
8.502 m
5.630 m
1.956 m
0.00 m/h
0.00 m/h
0.00 m/h
0.00 m/h
T=19.1
T=19.1
T=19.1
T=19.1
T=18.7
T=18.7
T=18.7
T=18.7
T=18.6
P
T=18.6
P
P
P
T=18.6
T=18.6
T.avg
T.avg
T.avg
T.avg
18.8 C
18.8 C
18.8 C
18.8 C
LC1
LC3
LC5
LC7
LC2
LC4
LC6
LC8
23 bar
20 bar
24 bar
26 bar
Accept
2...more
m
(2,000)
1,837
CT 6 Ullage
Hi.Hi
Alarm
Optional
Work
Stations in
network
Exit all
ExitBack
BuzzerStop
Figure 1-1 shows the TankRadar system with a number of the available options.
10
Third edition, June 1997
Figure 1-2. Parabolic
Antenna
Service Manual
The Saab TankRadar system is the main part of the Saab
Cargo Control system which includes the following optional
features:
• Cargo control functions with Saab TankRadar MaC
• Ballast level gauging and draft gauging with the
LevelDatic system
• Overfill and high level alarm system with Omicron
system
• Load calculation with Kockumation’s LoadMaster
The Work Station is used by the operator for monitoring of
tank ullages, temperatures, inert gas pressures and all the
other data that is handled by the Saab TankRadar. The Work
Station does the alarm handling of the measured values. The
Work Station communicates with other systems, such as load
calculators and electro-pneumatic level gauging systems (for
ballast etc.) and supervises the Transmitter and Level Unit
computers.
Figure 1-3. Cone Antenna
The Level Unit contains terminals for the intrinsically safe connection of the Transmitters. It contains the electronics used for processing the signals from the Transmitters, for calculating the tank parameters, such as trim/list corrected ullage, and for communicating with the Work Station.
The Transmitters measure the distance to the product surface
using a continuous radar signal. The Transmitters have an
Electronic Box that generates and processes the radar signal.
There are two types of Transmitters, one standard type with
a high performance Parabolic Antenna and another with a
Cone Antenna.
Optional equipment for each tank, such as temperature
sensors, inert gas pressure sensor or the Local Display, is
connected to a wire terminal inside the transmitter housing.
The inert gas pressure sensor is placed inside the transmitter
housing. The Local Display can display ullage, average temperature and inert gas pressure of the tanks.
Third edition, June 1997
11
Service Manual
1.1 Radar Principle
The radar transmitter on top of the tank emits microwaves
directed by an antenna towards the surface of the tank content. The echo from the surface is picked up by the antenna
again, and the difference in frequency between the transmitted and the reflected signal is directly proportional to the
measured distance, i.e. the ullage indication.
The radar waves are not affected by the atmosphere inside
the tank - aggressive chemicals, thick, sticky liquids or any
other tank media can be measured without restrictions.
The ideal condition for ullage measurement is a stable cargo
surface perpendicular to the radar beam.
Trim or list, foam and waves on the cargo surface and bottom
sludge weakens the radar echo. However, the radar echo is
usually strong enough for reliable measurements.
But in exceptional cases the radar echo can be lost during
turbulent loading/discharging, or with strong trim/list
angles, or when measuring close to the tank bottom.
Figure 1-4. An inclined cargo
level weakens the radar echo.
Trim/list angles of more than +
3
°
can lead to error in the
ullage measurement.
Figure 1-5. Waves on the
surface give a scattered and
weakened echo signal. Turbulent loading and discharging,
especially close to empty tank,
can lead to error in the ullage
measurement.
12
Third edition, June 1997
2 General Information
Note: If TankRadar system needs to be switched off, check with
officer in charge that it is OK to interrupt the operation of the
system.
2.1 Safety
When connecting equipment in hazardous areas, certain
requirements must be fulfilled to provide protection against
explosion . There are requirements both for the equipment in
the hazardous area on deck and for the associated equipment
in non-hazardous area.
The Saab TankRadar system is intrinsically safe and meets
the requirements of all the major classification societies. The
Transmitters and deck units connected to them, have the
following safety approval code:
• EEx ia IIC T4 according to EN50014 and EN 50020
(European Norm)
Service Manual
All other optional equipment such as Portable Readout System, separate high level alarm system, supplied by Saab
Marine Electronics, placed in hazardous areas, is also intrinsically safe and meets the requirements of all the major classification societies.
Intrinsic safety is based on the principle of restricting electrical energy available in hazardous-area circuits, so that any
sparks or hot surfaces, that may occur as a result of electrical
faults in components, are too weak to cause ignition. To
accomplish this, zener diodes and current limiting resistors
in the Level Unit restrict the maximum voltages and currents
into the Transmitters.
Intrinsic safety is the only technique accepted for Zone 0
hazardous areas. It is also safe for the crew or the service
personnel and it allows the equipment to be maintained
while the ship is in operation.
IMPORTANT!
For trouble shooting and repair work of intrinsically safe
equipment or associated equipment, the following rules need
to be strictly followed:
Third edition, June 1997
- Working permit
- Use only original spare parts from Saab Marine Electronics. Any replacement with non-recognized spare
parts will jeopardize the intrinsic safety.
13
Service Manual
- Use only a certified battery operated multimeter.
- Disconnection of live units in hazardous area is allowed. However, when replacing for example an Electronic Box, it is recommended to disconnect its wiring
in the safe area (in the Level Unit).
14
Third edition, June 1997
3 Work Station
Saab TankRadar
Window Overview Setup Group Trend Alarm
P
Hi.Hi
Alarm
Cargo System Fore
CT3
CT4
Ullage
Ullage
5.630 m
1.956 m
0.00 m/h
0.00 m/h
T=19.1
T=19.1
T=18.7
T=18.7
P
P
P
CT 6 Ullage
T=18.6
T=18.6
T.avg
T.avg
18.8 C
18.8 C
LC5
LC7
LC6
LC8
24 bar
26 bar
m
(2,000)
1,837
Wed Aug 24 20:05:30 1994
CT2
Ullage
8.502 m
0.00 m/h
T=19.1
T=18.7
T=18.6
T.avg
18.8 C
LC3
LC4
20 bar
2...more
Service Manual
Exit all
Help
ExitBack
CT1
Ullage
1.559 m
0.00 m/h
T=19.1
T=18.7
T=18.6
T.avg
18.8 C
LC1
LC2
23 bar
BuzzerStop
Accept
Optional wooden box for
PC when located under
monitor
Figure 3-1 shows the Work Station.
The Work Station is operated with a light pen. With the light
pen, the operator just points directly on the screen to activate
various functions. For input of, for example alarm limits, a
keyboard is included.
There is an on-line Help-function, providing direct access to
relevant help texts.
As an option, a number of Work Stations can be placed in
different locations and connected in a network, sharing data
and processing power with each other.
New software can be downloaded from the Work Station to
the various units in Saab TankRadar. The Work Station is also
used for on board configuration and service of the Transmitters, the Level Unit and the Work Station itself.
The Work Station-software runs under the real-time operating system QNX.
The operation of the Work Station is described in the Operating Manual. However, the Service part of the Work Station
software is described in this manual in chapter 3.7.
Third edition, June 1997
15
Service Manual
3.1 Description of the Work Station’s Cabinet
Caution: Always turn the Work Station PC off before removing
any cables at the back of the PC.
Note: On the inside of the Work Station there are parts that are
sensitive to static electricity. Be careful not to expose any of the
components inside to static electricity. Always ground yourself by
using a grounding wrist band or by touching something that is
grounded, before touching any of the components inside the Work
Station.
See maker’s manual (Hewlett-Packard) for description of the
Work Station PC. This is enclosed in the Saab TankRadar G3
manual binder.
The principle connection of the Work Station is shown on the
drawing “Work Station Connection - Principle Diagram” in
the “As-built drawings and user’s manual”-binder.
3.2 Replacing the Work Station’s Hard Disk
See chapters 9.2.1 and 9.2.5 in fault finding section for information on when to change the hard disk of the Work Station.
Remove the Work Station
1. Turn the power off.
2. Disconnect the mains lead.
3. Remove the PC from the ruggedizing kit.
4. See maker’s manual (Hewlett-Packard) for detailed
information on how to replace the hard disk.
3.3 Replacing a Work Station
Replace the Work Station either with a spare one or by replacing a master Work Station with a slave, if more than one
Work Station is included in the system. See fault finding
chapters 9.2.1 and 9.2.2 for more information on when it
might be necessary to replace the Work Station.
1. Remove all the connectors from both the slave and the
master Work Station.
2. On both Work Stations – remove the monitor as well as
front and top cover following the instructions in chapter 3.2.1 above.
3. Remove all optional boards (normally the Serial Interface Board and the Network Board) and place them in
the new Work Station or Slave Work Station. Make a
note of the ethernet address printed on the Network
Board.
4. Replace the covers and replace the monitor.
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Service Manual
5. Connect all connectors (that were previously connected
to the master) to the new master Work Station.
6. Start the new master Work Station.
7. Install program according to the instructions in chapter
3.6. During the installation, select this Work Station as
the master.
8. Install database according instructions in chapter 3.32.
9. Restart the Work Station by pressing the Reset-button
on the front.
If you have made a slave Work Station become a master,
follow the steps below to configure it as a master Work Station.
10. Open the Work Stations-window in the Configure part
of the Work Station software. Make a note of the
ethernet addresses.
11. Exchange the ethernet addresses between the master
and the slave Work Stations. Check that the address
corresponds with the note you made in step 3 above.
12. Restart the Work Station by pressing the Reset-button
on the front.
3.4 Replacing a Board in the Work Station
There are one or more boards, such as Light Pen Interface
Board, Serial Interface Board, Network Board, placed in the
Work Station. If you need to replace any of these boards,
follow the instructions below.
1. Remove the Work Station from its ruggedizing kit. For
opening the Work Station PC, follow the instructions in
the maker’s manual (Hewlett-Packard) enclosed in the
Saab TankRadar G3 manual binder.
2. Remove the faulty board’s connectors at the back of the
Work Station. Remove the faulty board. In some cases it
might be necessary to remove more than one board to
reach the faulty board.
3. Replace it with a new board. Connect cables to the
boards. If you are replacing a Network Board, make a
note of the ethernet address printed on it.
4. Mount cover of the Work Station.
5. Mount the Work Station on its ruggedizing kit and
connect monitor and other peripheral units.
6. If you have replaced a Network Board, open the Work
Stations-window in the Configure part of the Work
Station software.
7. Enter the ethernet address of the new board.
8. Restart the Work Station by pressing the Reset-button
on the front.
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Service Manual
3.5 Screen Settings of the Work Station Monitor
There are a number of controls below the monitor’s screen.
Whenever the picture on the screen looks distorted or incorrect, changing the screen settings may produce a better picture.
See maker’s manual (Hewlett-Packard) in the Saab TankRadar G3 manual binder for information on the monitor controls.
3.6 Loading Software to a Work Station
Follow the instructions below to install new software onto
the hard disk of the Work Station. This needs to be done, for
example, if the hard disk has been replaced.
The software consists of three parts: program, database and
pictures. This is complemented with your own backup copy
of database and pictures.
The program is stored on diskettes that are stored on board.
The first diskette is a boot-diskette which means that the PC
can be started on that diskette.
If any other diskette is in the drive when powered on, the
operator will be notified to remove it.
3.6.1 Install Program on Hard Disk of Work Station
1. Slide the Boot-diskette into the disk drive of the Work
Station.
2. Restart the Work Station by pressing the Reset button
on the front of the PC. The Work Station will now restart on the Boot-diskette in the disk drive.
3. Follow the instructions on the screen to install the new
program.
4. When the installation is finished the Work Station will
restart using the new program.
3.6.2 Install Database and Pictures on Hard Disk of
Work Station
Database and pictures are stored on a diskette. At the delivery of the TankRadar system, a diskette with files for database and pictures is included. As you make changes to your
system you should make backup copies of your database and
pictures. See chapter 3.32.
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Follow the instructions in chapter 3.32 to install database or
pictures onto the hard disk of the Work Station.
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Service Manual
3.7 The Service Windows of the Work Station Software
A number of the actions in the fault finding section at the end
of this manual suggest operations done on the Work Station.
The Service functions are protected by passwords. The Captain-password is required when:
- installing or backing up database and software in the
Service part of the Work Station software,
- downloading or uploading database to Level Unit or
Work Station in the Service part of the Work Station
software,
- adjusting IG pressure to zero in the Service part of the
Work Station software,
- disconnecting a channel,
- changing the Operator-password.
All other functions in the Service part of the Work Station
software require the Service-password. Contact Saab Marine
Electronics or one of the service agents to receive the Servicepassword. See list of service agents in chapter 12.
Hit the Window-button at the top of the Work Station screen.
Hit the Service-item on the menu to open the Service submenu. See figure 3-2.
In the service windows, the dynamic data and database
values are in separate boxes. Most of the data in the database
boxes can be changed. Where there is data that can be
changed (shown as underscored), there are two buttons;
Figure 3-2 shows the
Service menu and sub-
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menu.
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Service Manual
Undo and Save. Any data that is changed in these windows
is stored according to the settings in the destination part of
the Level Unit-window described below. The Undo-button
will change an entry, but only if it has not been saved. Once
you press the Save-button you cannot undo the entry (unless
you enter the previous value and press save again).
3.8 Level Unit – Version Summary and Database Status
This window shows the version and status of the databases
and programs in the LCI and LCMs. You can also see if one
or two LCMs are used.
There are status boxes for the different programs as well as
the dates for the last changes of the database in the Level
Unit.
This information can be useful if you need to contact Saab
Marine Electronics or one of the service agents.
3.9 Level Unit – Transmitter Data
[Window/Level Unit/Register/Tank Data/Transmitter]
The Transmitter Data-window shows the dynamic data from
a Transmitter, as well as the Transmitter’s status. The various
tank distances stored in the database are displayed in this
window. You can change these values in this window. It is
also possible to set the Level Unit to a one-tank measurement
mode, see chapters 3.25 and 3.14. It is also possible to restart
the transmitter by hitting the Restart Tank-button.
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Service Manual
Note: When setting the Level Unit into one-tank measurement
mode, there is no measurement on the other tanks.
Select a new tank by hitting the Tank-button or by hitting the
up or down arrow keys.
The tank number is the internal number in the TankRadar
system and is useful when setting the addresses on the optional Tank Display Units, see chapter 8.1. It is also the number that is used when communicating with other systems
such as load calculators or ship host computers.
The tank address corresponds to the terminal on the Transmitter Interface to which the Transmitter is connected. Tank
addresses 1-15 are connected to LI 1, addresses 16-30 to LI 2,
31-45 to LI 3 and 46-60 to LI 4.
The tank address is usually the same as the tank number.
However, they do not need not be the same.
The dynamic data is status or data that is continuously being
measured and presented. These values can not be changed
by the operator.
Third edition, June 1997
• Ullage is the distance from the TankRadar reference
point down to the surface of the product in the tank.
Innage is the distance from the bottom up to the surface
of the product.
• Level rate is the rate at which the surface of the product
moves as the tank is loaded or discharged. Positive
values indicate that the surface moves upwards.
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Service Manual
• Distance is the distance from a separate ullage plug,
included, to the surface of the product in the tank. It is
the ullage plus the A-distance and is T/L-corrected.
• Filter center is the location of the center of the measur-
ing filter during the last sweep. This value is normally
very close to the ullage value. It can differ when the
surface is close to the bottom of the tank or close to a
disturbing echo.
• Time stamp is a counter that shows that the transmitter
is operating.
• T/L corr cog shows the correction value used to adjust
the ullage value from the TankRadar reference point to
a trim and list corrected value at the center of gravity in
the tank. The centre of gravity is in this case the center
of gravity of the product’s surface (COF) when it is at
the 98% filling (volume) in the tank.
• T/L corr plug is the trim and list corrected ullage at a
separate ullage plug (same as A-measure).
• Ampl prefilt is the amplitude of the incoming signal
from the transmitter before it has passed any filters.
• Ampl postfilt is the amplitude of the filtered signal.
This is normally the strength of the surface echo. Read
the Amplitude postfilt when using the Transmitter Test
Cable, see chapter 6.2.
• Noice threshold. Any echoes with amplitudes less than
the noice threshold do not interfere with the measurement. This value is set to 350 mV as default. A normal
echo from an oil surface has an amplitude (Ampl
postfilt) of approximately 1500 to 2500 mV.
• Com err freq. Shows the frequency of communication
errors. Its value should be less than 10 (%/10). A larger
value could be an indication of, for example bad wiring.
The system should have been running for at least 15
minutes before this value shows a reliable figure. A true
indication of the communication performance is available after a few hours operation.
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The Transmitter status are shown as check boxes.
• TX comfail indicates that the transmitter is not commu-
nicating. This produces an alarm on the alarm row.
• TX failure. No echo has been found. The transmitter is
ordered to wait for a minute, then it starts searching
again. The ullage values displayed are the last valid
values. The ullage is not updated as long as TX failure
is checked.
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Service Manual
• TX ID switch on is checked when the button on the
Service Display is pressed or when positions 4 and 30
on WT500 on the transmitter has been jumpered.
• Corr plug inval is checked when the trim and list correction of the ullage cannot be done or when the calculation produces erroneous results. This holds true for
the Corr cog inval as well. This could be caused by
totally incorrect distances from the TankRadar Reference point to the tank’s reference point (center of gravity or separate ullage plug).
• TX active is checked when the LCM board requests the
transmitter to measure. However, this checkbox does
not automatically mean that the transmitter is working.
• Searching. The transmitter has lost the echo but is
searching for it.
• TX com timeout. A temporary break in the communica-
tion with the transmitter. Does not cause an alarm. The
box can be checked for a short while. However if it
remains for some time, the TX sens fail status will go
on resulting in an alarm.
• TX test fail. The LCM tests each transmitter regularly.
The transmitter sends a known frequency equalling a
certain ullage. The LCM calculates the ullage from the
test frequency and compares with the expected ullage.
If this box is checked there is also an alarm.
Note: If the TX failure is checked but the TX comfail is not,
try exchanging the Electronic Box.
• Clean Antenna. If the strength of the tank signal is
slowly weakened over a long period of time, the Clean
Antenna box is checked. The effect of both trim and list
on the strength of the tank signal are taken into account.
Note: The Clean Antenna warning may come up if the cargo
has extremely low reflectivity, such as certain chemical products.
Third edition, June 1997
A few of the database registers are shown in the window.
These registers can be changed and saved.
The tank distances displayed in the database box are explained in the Installation Manual, found in the "As-built
drawings and user's manual"-binder. The beam distances can
be used when there are disturbing objects in the tank. If
required, these distances are set by a service engineer when
the TankRadar system is commissioned. These beam distances should normally not be changed once the system has
been commissioned.
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Service Manual
• The A- and B-distances are explained in the Installation
Manual.
• The Beam 1-4 distances are used to filter out any dis-
turbing echoes in the tank, where Beam 1 is the lowest
in the tank. These values are programmed by a Saab
service engineer during the commissioning of the system. They should not be changed.
• Trim dist plug, List dist plug, Trim dist cog and List
dist cog are used to define how the correction of the
measured ullage should be corrected for trim and list
angles. Check if correction is done to a separate ullage
plug or to the center of gravity of the tank, in the window “SETUP: Drafts, Trim and List”. The trim distance
is positive when the TankRadar reference point is fore
of the separate ullage plug or the center of gravity. The
list distance is positive when the TankRadar reference
point is to starboard of the separate ullage plug or the
center of gravity.
• Trim dist plug is the longitudinal distance from the
TankRadar reference point to a separate ullage plug. It
is also called the C-distance, see the Installation Manual
for more information.
• List dist plug is the transversal distance from the
TankRadar reference point to a separate ullage plug. It
is also called the E-distance, see the Installation Manual
for more information.
• Trim dist cog is the longitudinal distance from the
TankRadar reference point to the center of gravity of the
products surface at 98% filling (volume) of the tank
(COF). It is also called the C-distance, see the Installation Manual for more information.
• List dist cog is the transversal distance from the
TankRadar reference point to the center of gravity of the
products surface at 98% filling (volume) of the tank
(COF). It is also called the E-distance, see the Installation Manual for more information.
• TX type describes which type of antenna that is used on
the tank.
- 0 indicates a special antenna,
- 1 indicates that the Parabolic Antenna is used,
- 2 indicates that the Cone Antenna is used,
- XX indicates that the Fast Opening Parabolic Antenna
is used.
- XX indicates that the Draught Antenna is used.
• Spec inner length is a theoretical distance correction for
the distance from the microwave unit to the TankRadar
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Service Manual
reference point. There is no need to enter a value here if
TX type is selected as 1 or 2.
• The Local Display Mode indicates which data the Local
Display should show.
- 0 switches the display off,
- 1 makes it show ullage continuously.
- 2 makes it toggle between ullage, average temperature
and inert gas pressure.
- 3 sets the display to show a value sent from the Work
Station. This feature is programmed prior to delivery of
the system. If no value has been defined, the feature is
not working.
- 4 sets the display to show ullage always in mm
- 5 sets the Local Display to show the tank address all
the time.
• FFT search. This indicates the method used to find the
echo when it has been lost. The FFT Search method is
set by the Saab service engineer when commissioning
the system. It should only be changed by a Saab service
engineer.
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Service Manual
3.10 Level Unit – Temperature Data
The Temperature Data-window shows the dynamic data and
the database values for the temperature measurement.
Select a new tank by hitting the Tank-button or by hitting the
up or down arrow keys.
The dynamic data box shows:
• Int temp. The internal temperature measured by a
sensor inside the Transmitter is displayed.
• Temp avg. The average temperature calculated as the
average of the values from the sensors that are immersed in the liquid.
• Temp 1, 2 or 3. The value from each individual sensor is
displayed.
The following status are shown:
Note: Temperature sensor number 1 is the lowest sensor. If only
two sensors are used, these will be number 1 and 2, with number 1
as the lowest.
• TX comfail indicates that the transmitter is not commu-
nicating. This produces an alarm on the alarm row.
• Int temp fail. The internal temperature measurement
has failed when the box is checked.
• Avg error. This box is checked if it was not possible to
calculate any average temperature. For example if there
is no temperature sensor in the liquid.
• Temp 1, 2 or 3 fail. This temperature sensor does not
produce an acceptable value.
• Int Temp valid. This box is checked when the internal
temperature sensor is producing an acceptable value.
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Service Manual
• Temp 1, 2 or 3 in liq. This box is checked when this
temperature sensor is immersed in the liquid, when it
has stabilized and when the ullage value is valid.
The following database data are shown and can be changed:
• L3, L2 or L1 type/range. This value shows if it is a
three-wire or four-wire type sensor that is used. The
temperature range is also defined by this value. The
following values can be shown:
• 0 for no connected temperature sensor.
• 1 for four-wire sensor with temperature range 0 to
+100°C.
• 2 for four-wire sensor with temperature range -50 to
+250°C.
• 5 for three-wire sensor with temperature range 0 to
+100°C.
• 6 for three-wire sensor with temperature range -50 to
+250°C.
• H distance. The H distance is explained in the Installa-
tion Manual.
Any changes of the database values must be followed by
hitting the Save-button as well as restarting the transmitter
by hitting the Restart TX-button.
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Service Manual
3.11 Level Unit – IG Pressure Data
The IG Pressure Data-window shows the dynamic data and
the database values for the IG pressure measurement.
Select a new tank by hitting the Tank-button or by hitting the
up or down arrow keys.
The dynamic data box shows:
• Pressure. The measured pressure.
The status boxes show:
• TX comfail indicates that the transmitter is not communicating. This produces an alarm on the alarm row.
• Press sens fail. The sensor is faulty. This status will also
be shown as an alarm.
• Press sens valid. This box is checked when the measurement is working well.
• Ext. press alarm. The extreme pressure alarm status is
an alarm for rapid detection of changes in the IG pressure. The alarm handling is done in the Transmitter,
and the alarm can therefore be displayed to the operator instantly.
The database box shows:
• Press sens type. The type of sensor can be set as:
- 0 for not connected sensor.
- 9 for ± 500 mbar type sensor.
• Pressure offset. The offset correction that has been
programmed for the sensor. The pressure offset is programmed by pressing the Service-button in the Level
Unit-window, see chapter 3.28 and 6.4.
• Ext alarm low and Ext alarm high. Set the high and low
alarm limits of the extreme pressure alarm.
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Any changes of the database values must be followed by
hitting the Save-button as well as restarting the transmitter
by hitting the Restart TX-button.
Third edition, June 1997
3.12 Level Unit – Extra Sensor Data
The Extra Sensor Data-window shows the dynamic data and
the database values for the two extra temperature sensors
that can be connected to each transmitter.
Select a new tank by hitting the Tank-button or by hitting the
up or down arrow keys.
Service Manual
The dynamic data box shows:
• Sensor 4 and 5. The temperature measured by the
sensors are displayed in 1/10 of degrees.
The following status are shown:
• TX comfail indicates that the transmitter is not commu-
nicating. This produces an alarm on the alarm row.
• Sensor 4 or 5 fail. The temperature sensor has failed
when its box is checked. This status will also be shown
as an alarm.
The following database data are shown and can be changed:
• Sensor 4 and 5 type. This value shows if it is a three-
wire or four-wire type sensor that is used. The temperature range is also defined by this value. The following
values can be shown:
• 0. No connected temperature sensor.
• 1. Four-wire sensor. Temperature range 0 to +100°C.
• 2. Four-wire sensor. Temperature range -50 to +250°C.
• 5. Three-wire sensor. Temperature range 0 to +100°C.
• 6. Three-wire sensor. Temperature range -50 to
+250°C.
• Sensor 4 or 5 offset. An offset can be set for each sensor
individually.
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Any changes of the database values must be followed by
hitting the Save-button as well as restarting the transmitter
by hitting the Restart TX-button.
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Service Manual
3.13 Level Unit – Trim/List Data
The Trim/List Data-window shows the measured trim and
list angles. They are displayed as 1/100 of degrees.
The source of the trim and list values are shown in the Ship
measures-window in the Configure-part of the software.
Open the Ship measures-window by hitting the Window-key
and selecting Configure. Then hit the Picture-button and
select Calculation and Ship data.
The dynamic data box is divided into three parts for LCI,
LCM 1 and LCM 2. The LCM 1 and 2 read trim and list values produced by the Trim/List Unit mounted in the Level
Unit cabinet. The LCI receives its trim and list values from
draft sensors, separate inclinometer, from external communication or if it is manually entered.
The status boxes show.
• Trim or list sens fail. The sensor in question is faulty.
• Trim or list manual. This box is checked if manual
values for trim and list have been entered.
In the database box the following is shown and can be
changed:
• LT sensor type. Enter 0 if no trim and list sensor is
connected. Enter a 1 if the standard Trim/List Unit is
used.
• Trim or list offset. If you find that the trim/list values
displayed by TankRadar are not correct, their offset can
be programmed in the database box. The offset is
shown in 1/100 degrees angle. For example, enter 5 to
set a 0.05° offset.
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