Varec 4000 User Manual

Page 1

4000 Tank Gauge Transmitter

Advanced Technology Transmitter for transmission of level and temperature data from the tankside to inventory management systems.

Installation and Operations Manual

IOM003GVAE1007

www.varec.com

5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA

Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939

Varec, Inc.

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4000

All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means- electronic, mechanical, photocopying, recording or otherwise- without the prior written permission of the Publisher:

Varec, Inc. 5834 Peachtree Corners East Norcross (Atlanta) GA 30096 USA

Trademarks acknowledged

Varec, Inc. recognizes all other trademarks. Trademarks of other products mentioned in this document are held by the companies producing them.

MODBUS® is a registered trademark of Modicon, Inc.

TIWAY® is a registered trademark of Texas Instruments Corporation.

HART® interface is a registered trademark of HART communications foundation.

Rosemount® and Smart Family® are registered trademarks, and HART is a trademark of Rosemount Inc.

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Tank Gauge Transmitter

Disclaimer of Warranties

The contract between the Seller and the Buyer states the entire obligation of the Seller. The contents of this document shall not become part of or modify any prior or existing agreement, commitment or relationship between the Seller and Buyer. There are no express or implied warranties set out in this document. The only warranties that apply are those in the existing contract between the Seller and Buyer.

Varec, Inc. products have not been tested by Varec, Inc. under all possible operational conditions, and Varec, Inc. may not have all the data relative to your application. The information in this document is not all inclusive and does not and cannot take into account all unique situations. Consequently, the user should review this product literature in view of his/her application. If you have any further questions, please contact Varec, Inc. for assistance.

Limitations of Seller's Liability

In the event that a court holds that this document created some new warranties, Seller's liability shall be limited to repair or replacement under the standard warranty clause. In no case shall the Seller's liability exceed that stated as Limitations of Remedy in the contract between the Seller and Buyer.

The information provided in this document is provided “as is” without warranty of any kind. Varec, Inc. disclaim all warranties, either express or implied, including the warranties of merchantability and fitness for a particular purpose. In no event shall Varec, Inc. or its suppliers be liable for any damages whatsoever including direct, indirect, incidental, consequential, loss of business profits or special damages, even if Varec, Inc. or its suppliers have been advised of the possibility of such damages.

Use of parts that are not manufactured or supplied by Varec, Inc. voids any Varec, Inc. warranty and relieves Varec, Inc. of any obligation to service the product under warranty. Varec, Inc. recommends the use of only Varec, Inc. manufactured or supplied parts to maintain or service Varec, Inc. products.

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Safety Precaution Definitions

Caution! Damage to equipment may result if this precaution is disregarded. Warning! Direct injury to personnel or damage to equipment which can cause injury to

personnel may result if this precaution is not followed.

Safety Precautions

READ AND UNDERSTAND THIS INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR PERFORMING MAINTENANCE ON VAREC 4000 SERIES TANK GAUGE TRANSMITTER. FOLLOW ALL PRECAUTIONS AND WARNINGS NOTED HEREIN WHEN INSTALLING, OPERATING OR PERFORMING MAINTENANCE ON THIS EQUIPMENT.

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1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Getting Acquainted with the Advanced Technology Transmitter (ATT) . . . . .1

1.4 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.5 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1.2 Storage Prior to Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1.3 Becoming Familiar with the ATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.1.4 Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.3 Grounding the Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.1 ATT Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.2 Wiring Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.3 Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.4.4 Connecting Host Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.5.1 Connecting the Handheld Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.2 Wiring Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.3 Installation Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.5.4 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.1 Configuration Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.2 1200 Hand Held Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.3 Terminal Mode Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.4.5 Notes on Menu Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.5 Quick Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.5.6 Imperial Decimal 1800 Series Transmitter Quick Setup . . . . . . . . . . . . . . .24

3.5.7 0-20 Meters 1800 Series Transmitter Quick Setup. . . . . . . . . . . . . . . . . . .24

3.5.8 0-30 Meters 1800 Series Transmitter Quick Setup. . . . . . . . . . . . . . . . . . .24

4 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .27

4.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.2 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

4.3.1 ATT Error Status Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.5 ATT Configuration Error Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

4.7 Host Communication Loopback Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5.1 Specifications and Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . 31

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5.1.1 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.2 Physical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.3 Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1.4 Level Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.2.1 Explosion Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2.2 Intrinsic Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6 Order Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.2 CPU Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.3 Status Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.4 ATTI Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.5 Host Communications Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.6 Level Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Tank Gauge Transmitter

7.6.1 Back-up Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.6.2 Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.7 Encoder Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.8 Temperature Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.9 Host Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.10 Mark/Space Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.11 Modbus Support over Mark/Space Host Interface. . . . . . . . . . . . . . . . . . . . 41

7.12 Compatibility with Varec Tank Polling Unit . . . . . . . . . . . . . . . . . . . . . . . . . 41

8 ATT Family of Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.1 Model 4040 Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.2 Model 4050 Digital Input/Output Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2.1 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2.2 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2.3 Relay Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9 Modbus Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.2 Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9.5 Integer Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9.5.1 Integer Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9.5.3 Character Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.5.5 Packed Bit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9.6.1 Floating-Point Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.6.2 The Two 16-bit Registers Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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9.6.3 Floating Point Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

9.6.5 Floating Point Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

9.6.6 Floating Point Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

9.7.1 Status Bit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

9.8 Exception Responses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

9.10 Loopback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

9.11 Hardware Implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

9.12 Integer Register Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

9.14 Status Bit Register Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

10 Optional Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.1 4000TIFMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.2 4000GEFMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.3 4000LJFMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.4 4000MXFMO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.6 4000GMFMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

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4000 Introduction

1 Introduction

1.1 Using This Manual

This manual is designed to assist the user with the installation, configuration, operation, maintenance, and troubleshooting of the Varec Model 4000 Advanced Technology Transmitter (ATT).

1.2 Getting Acquainted with the Advanced Technology Transmitter (ATT)

The Varec Model 4000 Advanced Technology Transmitter (ATT), in conjunction with a host, represents a data acquisition and communications system for use in liquid level measurement and/or other measurement applications. Liquid level measurement is provided by the Advanced Technology Transmitter coupled to a Varec Model 2500 or other level gauge, as shown in Figure 1-1.

Tank Gauge

and

Transmitter

Power

Loop

Communcations

3-wire

RTD

8130 RTU

FuelsManager

Software

8300 TGI

CPU

+24V

+5V

COMM

I/O

+15V

ERROR

-15V

Communications

between DCS/PLCs

for control capabilities

Field

Junction Box

Star Communcations e.

Figure 1-1: Tank Installation with Model 4000 ATT

Loop Communcations

. Mark/Space

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Introduction Tank Gauge Transmitter

1.3 Operation

The ATT uses an incremental counting technique for determining liquid level. An initial level is identified as part of the calibration procedure. Changes to that level are determined through incremental increases or decreases detected by the ATT.

The host computer collects measurement information by polling the Advanced Technology Transmitter over a variety of communication interfaces such as EIA485 and Mark/Space. Several communication protocols are supported. Among them are Modbus and Mark/Space.

1.4 Configuration

The Varec Model 1200 Handheld Terminal is used to configure the ATT. It connects to the same ATTI bus used to interconnect other input/output devices to the ATT. There is a special connection located inside the junction box for the Handheld Terminal.

1.5 Construction

The Advanced Technology Transmitter is housed within an aluminum enclosure. The enclosure and assembly meet explosion proof requirements and are environmentally sealed to prevent internal exposure to contamination.

7.5 "

(190 mm)

12 "

(308 mm)

4 "

(101 mm)

3.7 "

(94 mm)

Figure 1-2: Model 4000 Advanced Technology Transmitter Assembly

3.4 "

(86 mm)

8 "

(203 mm)

6.8 "

(172 mm)

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4000 Installation

2 Installation

2.1 Overview

This section contains instructions for unpacking, mounting, grounding, and wiring the Varec Model 4000 Advanced Technology Transmitter (ATT) assembly. An installation checklist is also included.

Warning! To avoid electric shock and possible injury, do not perform any service procedures other than those specified in this

manual. These installation instructions are for use by qualified service technicians.

Figure 2-1: Model 4000 ATT mounted on Model 2500 ATG

2.1.1 Unpacking

Remove the ATT from the shipping container and inspect it for evidence of shipping or handling damage. Report any shipping damage to the carrier. Verify that the contents of the shipping container agrees with the packing list.

2.1.2 Storage Prior to Installation

If the ATT is to be stored prior to installation, it should be repackaged in its shipping container and stored in a temperature and humidity controlled environment.

2.1.3 Becoming Familiar with the ATT

The ATT is housed within an explosion proof enclosure. A cover is provided to permit access to both the electronics and backup batteries.

3/4- and 2 1/2-inch NPT plugs are provided for wiring access. Wiring to the ATT consists of connecting power, host communication, RTD input and an optional ground connection.

2.1.4 Hardware Configuration

All configuration is performed using the Model 1200 Handheld Terminal or a download from a host computer. However, certain parameters such as communication address and speed must be configured via the Model 1200 Handheld Terminal.

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Installation Tank Gauge Transmitter

2.2 Mounting the Equipment

The ATT is bolted to the Model 2500 Automatic Tank Gauge head as illustrated in Figure 2-2. It may also be mounted to Endress+Hauser, Sakura, Tokyo-Keiso, Shand & Jurs, and Gauging Systems, Inc. float and tape gauges with the Endress+Hauser adapter shown in the following table.

Part Number Gauge Adapter Kit

13-05956-102 L&J (Shand & Jurs) 92513, 92514, 92020, 92030

13-05956-202 Whessoe 2006, 2026, 2036 and L&J (Shand & Jurs) 92006

Mounting the ATT to the Level Gauge is accomplished in the following manner:

1. Remove the back cover of the Level Gauge.

2. Remove the access cap from the back cover of the Level Gauge.

3. Mount the ATT in place of the access cap, making certain that the word "TOP" cast into the housing lines up with the top of the Level Gauge back cover.

4. Install the Level Gauge back cover with the transmitter in the Level Gauge. Make certain that the slot in the ATT drive coupling engages with the pin on the tape sheave of the Level Gauge.

5. Proceed with field wiring.

Back cover

Junction

box cover

Integral junction

box

Drive coupling

5/16-18 X 1 mounting bolts (4 places)

5/16 split lock washers (4 places)

Transmitter

Pin drive

Sprocket Sheave

2500

Automatic

Tank Gaug

Back Cover

xternal enclosure ground connection by installer

External Ground Lug

Gauge cover mounting

bolts (15 places)

Figure 2-2: ATT Mounting Diagram

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4000 Installation

2.3 Grounding the Equipment

Warning! The ATT must be grounded before communication and power connections are made.

An external grounding lug is provided on the ATT. A connection from the ground lug to earth ground must be made before any other wiring connections are made.

Note! For adequate/proper operation of the ATT lightning arrestor, a ground strap must be attached to the ATT. Grounding

through mounting kits or pipe coupling is not adequate.

Note! Properly seal all ports to prevent moisture or other contamination from entering the wiring compartment.

2.4 Wiring

Connections should be made in a conventional manner according to local or plant electric codes.

Warning! Explosion-proof seals must be installed in all wiring entries. Any unused entries must be plugged with pipe plugs and

secured with Loctite®, or equivalent.

2.4.1 ATT Wiring

Wiring the ATT is described in the following paragraphs. The wiring diagram provided in Figure 2-3 on page 6 should be used in conjunction with these wiring instructions.

2.4.2 Wiring Preparation

Remove the two thread protectors from the 1/2-inch NPT conduit entries at the top and bottom of the ATT. Remove the rear cover from the ATT housing.

2.4.3 Connecting Input Power

Warning! When connecting DC power leads to the ATT, make certain that power is OFF.

The ATT operates on a 24-48 volts DC power source. The input power connection to the ATT is accomplished in the following manner.

Connect the positive side of the power supply to terminal 10, B+, and the negative side to terminal 9, B-, of the terminal block assembly. See Figure 2-3 on page 6.

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Installation Tank Gauge Transmitter

Figure 2-3: ATT Field Terminal Block Wiring

Terminal Block One TB1 Terminal Block Two TB2

1 L+ = ATTI expansion Bus +

power

2 HPORT = ATTI bus HART Signal 11 M = Mark or EIA485 -

3 L- = ATTI expansion Bus -

power

4 C = RTD C lead 9 B - = ATT - power

5 B = RTD B lead 8 -- = Reserved

6 A = RTD A lead 7 -- = Reserved

12 S = Space or EIA485 +

10 B + = ATT + power

2.4.4 Connecting Host Communication

The procedure used to wire the ATT to the host computer depends on the type of host interface option ordered with the ATT.

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4000 Installation

2.4.5 ATT EIA485 Wiring

The ATT uses a 2-wire EIA485 hardware interface to communicate with the Modbus master. EIA485 is a high speed differential communications network which allows up to 32 devices to operate on one network. The ATT and Modbus master share a twisted pair of wires to communicate. Figure 2-4 illustrates the typical EIA485 wiring.

The communication distance that EIA485 can reliably travel is dependent on baud rate (communication speed), wire quality, environmental noise, wiring configuration, and the number of multi-dropped ATTs. The recommended wire for EIA485 systems is 18-gauge or larger, shielded, twisted pairs. The shield should be earth grounded at the Modbus master (control system or computer end). The shield at the ATT should be open. The ATT B- power line acts as a common reference tie to the Modbus master. Figure 2-5 on page 8 illustrates the EIA485 Modbus system.

TB2

Power Supply

+48 VDC Common

Figure 2-4: Typical EIA485 Wiring

RTU 8130 with 8230 expansion module

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Installation Tank Gauge Transmitter

Field Junction Box

Model 4000 ATT

Transmitters*

Model 4000 ATT

* Up to 31 units with 5000 ft. max. wiring distance using good quality wire.

Two 18 AWG twisted pair cables

Field Junction Box

EIA85 comm. with MODBUS to FIC

Two 18 AWG twisted pair cables

Transmitters*

Area 0

Area 1

RTU 8130

Model 8130 with optional 48 VDC power supply.

110/220 VAC 50/60 Hz.

RS232 To FuelsManager or other MODBUS master

RS232 serial port

50 feet max to FIC

Office Printer

Host Computer Interface

certified by Honeywell

FuelsManager

MODBUS interface is

Figure 2-5: Typical EIA485 System Wiring

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4000 Installation

2.4.6 ATT Mark/Space Wiring

For an ATT using the Mark/Space field communications option, the following additional wiring connections must be made. (Refer to Input Power Wiring in Section 6 to determine the minimum wire size required.). See Figure 2-6.

• Run two twisted pairs of 18 AWG wire (Mark/Space wires) into the ATT through the conduit entry along with the

48 VDC power wiring.

• Connect the Mark line to terminal 11, M/485-, and the Space line to terminal 12,

S/485+, on the terminal block assembly.

8203 With 8210

expansion module

Field Junction Box

4 Conductor

Cable 18 AWG Shielded

To Other

4-Wire

Transmitters

in Area 0

Ground shield at RTU8130 ONLY!

Do NOT ground shield at transmitter.

Details of RTU8130 with 8210 expansion module and ATT termination board wiring

External Power Supply

Varec

Model 4000

ATT

Figure 2-6: Typical Mark/Space Field Wiring

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Installation Tank Gauge Transmitter

2.5 Connecting the RTD

The following list shows how the ATT is wired to an RTD device. The ATT’s temperature circuit is designed to work with a platinum or copper 3-wire RTD.

2.5.1 Connecting the Handheld Terminal

Figure 2-3 on page 6 shows how the 1200 Hand Held Terminal is connected to the ATTI bus on the ATT. The Model 268 can also be used to configure the ATT.

Warning! The 1200 Hand Held Terminal on the ATT is not Intrinsically Safe. Care must be taken to only use in a non-hazardous

environment

Wire as follows:

• Connect the RTD's A terminal to the ATT's terminal 6, A.

• Connect the RTD's B terminal to the ATT's terminal 5, C.

• Connect the RTD's C terminal to the ATT's terminal 4, C.

2.5.2 Wiring Completion

Caution! Do not overtighten metal plugs used to seal wiring compartment ports. Overtightening may damage the housing.

Properly seal the 1/2-inch NPT conduit entry. Install cover and tighten to ensure that the O-ring seal is adequately compressed. Proper sealing of all ports is necessary to prevent moisture or other contamination from entering the wiring compartment.

2.5.3 Installation Checkout

After a thorough check that all connections are correctly made and that all covers and plugs are installed, turn on power to the ATT. Proceed to Chapter 3, Configuration.

2.5.4 Installation Checklist

The steps required in the installation process are summarized in the following checklist. Since each step is detailed specifically with accompanying notes, cautions, and warnings, be sure to refer to the sub-sections indicated for further information.

Step Sub-Section(s) Reference

Unpack the ATT and check the packing list. Unpacking

Verify that the required input power is available. Mounting the ATT, Wiring

Mount the ATT. Mounting the Equipment

Ground the ATT. Grounding the Equipment

Route the conduit between the ATT and other devices and seal all ports.

Wire the host communications. Connecting Host Communication

Wire the RTD Connecting the RTD

Wire the input power connections. Connecting Input Power

Apply power to the ATT. Installation Checkout

Wire the Model 1200 Handheld Terminal Connecting Handheld Terminal

Proceed to ATT configuration procedure. ATT Configuration (Section 3)

Wiring Completion

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4000 Configuration

3 Configuration

The Varec Model 4000 Advanced Technology Transmitter (ATT) must be configured for the specific tank, attached sensors, and host interface. This section provides detailed information on ATT configuration.

The ATT can be configured with a 1200 Hand Held Terminal or from a host program such as Varec TankView.

3.1 Configuration Parameters

Configuration parameters associated with ATT operation are entered and modified using the Model 1200 and can be divided into the following areas:

• General Configuration - includes units of measure, level calibration, temperature type selection, and alarm

setpoints.

• Host Configuration - includes the type of host interface used, baud rate selection, and emulation modes for other

level transmitters.

3.2 1200 Hand Held Terminal

The ATT can be used with a 1200 Hand Held Terminal, see Figure 3-3 on page 13. The Model 1200 provides a local terminal interface to configure the ATT and encoder at tankside. It is connected to the ATTI bus. It can be physically attached via two banana plugs located inside the terminal block housing.

The ATT uses the Model 1200 in a different mode of operation. Normally, the Model 1200 polls the ATTI BUS device, recognizes it, and goes into an internal menu system that is specifically tailored to that ATTI Bus device. The ATT however, uses the Model 1200 in what is called ASCII Terminal mode. In this mode, the Model 1200 sends keyboard activity to the ATT and displays screen information from the ATT. The ATT can not be configured with the Rosemount Model 275 Terminal.

Because of the way the ASCII Terminal mode works on the Model 1200, the ATT is unable to poll any ATTI BUS device while communicating to it. The ATT goes from an operational mode to an off-line mode. The operational mode is automatically switched to when the Model 1200 is removed from the ATTI BUS bus.

Warning! The 1200 Hand Held Terminal on the ATT is not Intrinsically Safe. Care must be taken to only use in a non-hazardous

environment.

Function keys F1 through F4, defined in Figure 3-1 on page 11, are used for basic scrolling of the ATT menus and selection of configuration parameters.

Function Key Description

HELP Help Message

F1 Scroll Up

F2 Scroll Down

F3 Alter/Backspace

F4 Enter

Previous Function [Ü] Return to previous menu or abort data entry

Table 3-1: Model 1200 Function Keys

Alpha and numeric information is entered from the keypad directly. Numeric data is entered using a single keystroke, while alpha information is entered with a two-key combination. The two-key combination for alpha data consists of a

shift key followed by a numeric key to select the desired alpha character.

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Configuration Tank Gauge Transmitter

For example, to enter the alpha character "N"; first press the shift key, then press the number 4. To enter the alpha character "R"; first press the shift key, then press the number 1.

Terminal Mode Configuration

When the Model 1200 is connected to the ATTI Bus and turned on, a blank screen will appear on the Model 1200 after a self test sequence. Pressing any key will cause the following screen to appear on the Model 1200 display:

The version indicated is the software version of the ATT.

Enter a "D" (to select Display Mode entries) or an "A" (to select Alter Mode entries) and press F4 (Enter).

If the Display Mode is selected with a "D", current status and configuration data may be examined but cannot be modified. This mode is useful for verifying ATT configuration. This mode cannot be used to actively monitor ATT operation, as normal ATT operation is suspended when the Model 1200 is connected.

Figure 3-1: ATT Alter Mode Menu Tree

If the Alter Mode is selected with an "A", all applicable configuration parameters can be modified. Figure 3-2 on page 12 illustrates the display mode menu tree and Figure 3-1 on page 12 illustrates the Alter Mode menu tree. The menu tree groups related items under separate menus and sub-menus. The menu grouping is provided to permit the field operator to configure and display items in a related and logical order. Once a menu is selected, the operator can scroll through related items.

Figure 3-2: ATT Display Mode Menu Tree

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4000 Configuration

ON / OFF

Previous Function

Shift

Figure 3-3: 1200 Hand Held Terminal

3.3 Terminal Mode Operation

The 1200 Hand Held Terminal is used to scroll through the various ATT menus. Basic scroll and selection operations are performed using the four function keys (F1 through F4) immediately below the display.

Line 1 of the display contains the menu title. Lines 2 and 3 are item display lines. Line 4 is an error message/status line.

If the item displayed on line 2 is preceded with an "M>", the item being displayed is a menu. You can select the menu by pressing F4 (Enter). If the item is preceded by a "C>" the item being displayed is a command that can be executed by pressing F4 (Enter).

Where:

F1 = Up F2 = Down F3 = Alter F4 = Enter

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Configuration Tank Gauge Transmitter

3.4 Menu Operation

For example, when the Main Menu is displayed on the top line, pressing F1 (Up) will scroll up through the possible main menu selections while pressing F2 (Down) will scroll down through the possible main menu selections.

Pressing F4 (Enter) will cause the selection of the sub-menu displayed on lines two and three (such as Config Menu). Scrolling through a sub-menu is performed in the same manner as scrolling through the Main Menu using the F1 and F2 keys.

To return to the Main Menu, press the PREVIOUS FUNCTION key [Ü], as shown in Figure 3-3 on page 13.

When a parameter is encountered which is to be changed, pressing the F3 key (Alter) will cause the display of the current parameter in a form which permits its modification.

When a specific set of parameters is available, the F1 and F2 keys can be used to scroll through the valid selections. When the desired selection is displayed, pressing the F4 key (Enter) will cause selection of the new parameter. When the parameter consists of numeric or free format characters, the Model 1200 keyboard can be used to enter the parameter. Note that parameter alteration is not final until the session is completed with the EXIT AND SAVE command from the Main Menu.

To complete parameter alteration, scroll through the Main Menu until the following display is presented, then press F4 (Enter) to exit and save the altered parameters.

If parameter alteration is to be aborted (new parameters not saved), scroll through the Main Menu until the following display is presented and press F4 (Enter) to quit without saving alterations. The QUIT or EXIT AND SAVE commands must be initiated before turning off or disconnecting the 1200 Hand Held Terminal.

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4000 Configuration

3.4.1 Main Menu

Main Menu Description

Quick Setup

Summary Menu

Config Menu Contains ATT configuration menu items. See table below.

Host Menu

Exit and Save

Initializes the ATT configuration parameters to a variety of preset configurations. Eng Frac 1900, Eng Dec 1900, 0-30 m 1900, 0-20m 1900, Eng Frac 1800, Eng Dec 1800, 0-30 m 1800, 0-20m 1800, Imperial Modbus, or Metric Modbus are valid. Use F1/F2 keys to select. See section below for details.

Warning! Warning! Using Quick Setup will overwrite any old

configuration in the ATT and should not be used if only some configuration parameters are to be changed.

Contains the ATT's process variable data and diagnostic status conditions. See table below.

Contains ATT host communication related configuration menu items. See table below.

Must be used to exit the Alter Mode if configuration data modified are to be used.

Quit/Exit Used to quit Alter Mode without saving. Also displayed as Exit

in display mode.

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Configuration Tank Gauge Transmitter

3.4.2 Summary Menu

Summary Menu Description

Level Current level.

Temperature Current temperature

RTD Resistance RTD resistance measured

Cfg Error Type Configuration error type detected.

Power Log Number of times unit has gone through a power down cycle

since it was last configured. Going into Alter Mode and using 'Exit and Save' resets this value to 0.

Bad CPU Board Stat

Bad RAM Stat

Bad EProm Stat

Bad EEProm Stat

Bad EECksum Stat

Bad Comm Board

Bad Level Stat

Bad Temp Stat

Low Battery Stat

Crit Hi Level Stat

Adv Hi Level Stat

Adv Lo Level Stat

Crit Lo Level Stat

Crit Hi Temp Stat

Adv Hi Temp Stat

Adv Lo Temp Stat

Crit Lo Temp Stat

Bad CPU Board Stat3True if the RAM, ROM, or EEPROM are bad.

True if RAM status is bad.

True if EProm status is bad.

True if EEProm status is bad.

True if EEProm checksum does not match the data stored in it.

True if communication board failed loopback test

True if level is bad.

True if temperature input is out of range.

True if battery voltage is low or no battery is connected.

True if the level is above the critical high level setpoint

True if the level is above the advisory high level setpoint

True if the level is below the advisory low level setpoint

True if the level is below the critical low level setpoint

True if the temperature is above the critical high temperature setpoint

True if the temperature is above the advisory high temperature setpoint

True if the temperature is below the advisory low temperature setpoint

True if the temperature is below the critical low temperature setpoint

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4000 Configuration

3.4.3 Configuration Menu

Configuration Menu Description

Level Units Level units used for display and Modbus data. FT-IN-16TH, M,

or FT are valid. Use F1/F2 to select.

Temp Units Temperature units used for display and Modbus data. F, C, or K

Level Sensor Direction of gauge. Forward/Reverse

Calib Level2 Command used to calibrate to a new level. Pressing F4 causes

Batt Off2 Command used to turn the battery off. Pressing F4 causes the

Damping Damping value used for level and temperature readings. 0-16

Temp Sensor Type of temperature sensor attached. None, Copper RTD, or

Manual Temperature If there is no temperature sensor, this is the value displayed

Noise Reject Sets up the noise rejection for the A/D. 50 and 60 Hz are valid.

Critical High Level Critical high level alarm setpoint.

Advisory High Level Advisory high level alarm setpoint.

Advisory Low Level Advisory Low LevelAdvisory low level alarm setpoint.

Critical Low Level Critical low level alarm setpoint.

Level Deadband Deadband used for level alarms.

are valid. Use F1/F2 to select.

ATT to ask for the current level to be entered.

battery to be turned off.

is valid.

Platinum RTD are valid. Use F1/F2 to select.

and returned for temperature.

Use F1/F2 to select.

Critical High Temp Critical high temperature alarm setpoint.

Advisory High Temp Advisory high temperature alarm setpoint.

Advisory Low Temp Advisory low temperature alarm setpoint.

Critical Low Temp Critical low temperature alarm setpoint.

Temp Deadband Deadband used for temperature alarms.

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Configuration Tank Gauge Transmitter

3.4.4 Host Menu

Host Menu Description

Type Type of host communication interface. Modbus or Mark/Space.

Use F1/F2 to select.

Mark/Space Adr

Low Speed

Xmtr to Sim

Encoder to Sim

Disable Temp Reply

ASU Connected

Temp to Sim

Offset Temp By 100

Low Battery

Modbus Address

Baud

Parity

Stop Bits

Max Integer

Min Level

Max Level

Min Temp

Max Temp

Address of ATT on Mark/Space bus. 0-999 is valid.

Whether or not to use low speed on Mark/Space bus. Yes or No is valid.

Type of Mark/Space transmitter to simulate. 1800 or 1900 are valid. Use F1/F2 to select.

Type of level encoder to simulate on the Mark/Space bus. Eng Frac, Eng Dec, 0-20m , or 0-30m are valid. Use F1/F2 to select.

If 'YES' disables the temperature portion of the reply on the Mark/Space bus and answer with only a 40 bit reply.If 'NO' the standard 56 bit message is returned with level and temperature. This only applies to the 1800/1900 reply mode for compatibility. Yes or No are valid.

If 'YES' replies with the level using a 39 bit message. The ASU is expected to be connected to the Mark/Space bus and will add the temperature portion of the reply to complete a 56 bit response. Yes or No are valid.

Temperature units to simulate on the traditional Mark/Space reply. F or C are valid. Use F1/F2 to select.

If 'YES' the temperature returned to the Mark/Space host is offset by 100 degrees. This only applies to the 1800/1900 reply mode for compatibility while emulating these transmitters.

Determines how low battery status is to be reported using the old 1800/1900 reply. None, HwIn1, HwIn2, or Bad Level are valid. Use F1/F2 to select.

Address of ATT on the Modbus bus. 1-254 is valid.

Serial baud rate used. 300, 600, 1200, 2400, 4800, and 9600 are valid. Use F1/F2 to select.

Parity used for serial communications. None, Odd, and Even are valid. Use F1/F2 to select.

Number of stop bits used for serial communications. 1 or 2 is valid.

Maximum integer value used to indicate a full scale value for scaled integer registers. 0 - 65535 is valid.

Value corresponding to a 0% scaled level value.

Value corresponding to a 100% full scale level value.

Value corresponding to a 0% scaled temperature value.

Value corresponding to a 100% full scale temperature value.

3.4.5 Notes on Menu Items

Only displayed if in Display Mode

Only displayed if in Alter Mode

Only displayed if TRUE

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4000 Configuration

Only displayed if host interface type is Mark/Space

Only displayed if host interface type is Modbus

Only displayed if host interface type is Modbus or Mark/Space

Only displayed if there is no temperature sensor

3.5 Quick Setup

The Quick Setup option is meant to get the ATT configured quickly and with some defaults. It is NOT likely that this configuration will match your installation exactly. However, after the Quick Setup option is selected, you can go through the 1200 Hand Held Terminal menus to see and modify any parameter. Quick Setup simply gives you a starting point.

Warning! The Quick Setup option erases all previous configurations in the A TT's EEPROM. If you use the quick setup command

from the 1200 Hand Held Terminal and you change your mind, simply exit the 1200 Hand Held Terminal Main Menu using the QUIT command. This works since no configuration is changed or used unless the EXIT AND SAVE command is executed from the Main Menu.

Please note that Quick Setup also configures all alarm setpoints to such values as not to generate alarms. You must modify the alarm setpoints to match your tank dimensions and your product.

The quick setup default configurations are:

• Imperial fractional 1800

• Imperial decimal 1800

• 0-20 meters 1800

• 0-30 meters 1800

• Imperial fractional 1900

• Imperial decimal 1900

• 0-20 meters 1900

• 0-30 meters 1900

• Imperial Modbus

• Metric Modbus

• Matrix 1600 Metric

• Matrix 1600 Imperial

• Matrix 1700 Metric

• Matrix 1700 Imperial

• Matrix 1700 Metric0-20 meters

• Matrix 1700 Imperial 0-30 meters

• Matrix 2400 Metric 0-20 meters

• Matrix 2400 Imperial 0-30 meters

• LNJ Metric

• LNJ Imperial

• Whessoe Bus Matrix

• Whessoe Bus Imperial

• GSI Modbus integer scaled

• GPE loop

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Configuration Tank Gauge Transmitter

3.5.1 Imperial Fractional 1900 Quick Setup Defaults

General Configuration

Level Units FT-IN-16th

Temp Units F

Level Sensor Forward

Damping 0

Temp Sensor Copper RTD

Manual Temperature

Critical High Level 80-0-0

Advisory High Level 80-0-0

Advisory Low Level 0

Critical Low Level 0

Level Deadband 0-1-0

Critical High Temp 500

Advisory High Temp 500

Advisory Low Temp 0

Critical Low Temp 0

Temp Deadband 1

Host Configuration

Type Mark/Space

Address 999

Low Speed N

Transmitter to Simulate 1900 MWT

Encoder to Simulate Eng Frac

Return Temp Y

Temp To Simulate F

Offset Temp by 100 Y

Low Battery Indication HwIn1

Max Integer Value 9999

Minimum Level 0

Maximum Level 80-0-0

Minimum Temperature 0

Maximum Temperature 500

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4000 Configuration

3.5.2 Imperial Decimal 1900 Quick Setup Defaults

General Configuration

Level Units FT-IN-16th

Temp Units F

Level Sensor Forward

Damping 0

Temp Sensor Copper RTD

Manual Temperature

Critical High Level 80.00

Advisory High Level 80.00

Advisory Low Level 0

Critical Low Level 0

Level Deadband 0.83

Critical High Temp 500

Advisory High Temp 500

Advisory Low Temp 0

Critical Low Temp 0

Temp Deadband 1

Host Configuration

Type Mark/Space

Address 999

Low Speed N

Transmitter to Simulate 1900 MWT

Encoder to Simulate Eng Dec

Return Temp Y

Temp To Simulate F

Offset Temp by 100 Y

Low Battery Indication HwIn1

Max Integer Value 9999

Minimum Level 0

Maximum Level 80.00

Minimum Temperature 0

Maximum Temperature 500

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Configuration Tank Gauge Transmitter

3.5.3 0-20 Meter 1900 Quick Setup Defaults

General Configuration

Level Units Meters

Temp Units C

Level Sensor Forward

Damping 0

Temp Sensor Platinum RTD

Manual Temperature 0.0

Critical High Level 20.0

Advisory High Level 20.0

Advisory Low Level 0

Critical Low Level 0

Level Deadband 0.03

Critical High Temp 250.0

Advisory High Temp 250.0

Advisory Low Temp 0

Critical Low Temp 0

Temp Deadband 1

Host Configuration

Type Mark/Space

Address 999

Low Speed N

Transmitter to Simulate 1900 MWT

Encoder to Simulate 0-20M

Return Temp Y

Temp To Simulate C

Offset Temp by 100 N

Low Battery Indication HwIn1

Max Integer Value 9999

Minimum Level 0

Maximum Level 20.0

Minimum Temperature 0

Maximum Temperature 250.0

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4000 Configuration

3.5.4 0-30 Meter 1900 Quick Setup Defaults

General Configuration

Level Units Meters

Temp Units C

Level Sensor Forward

Damping 0

Temp Sensor Platinum RTD

Manual Temperature 0.0

Critical High Level 30.0

Advisory High Level 30.0

Advisory Low Level 0

Critical Low Level 0

Level Deadband 0.03

Critical High Temp 250.0

Advisory High Temp 250.0

Advisory Low Temp 0

Critical Low Temp 0

Temp Deadband 1

Host Configuration

Type Mark/Space

Address 999

Low Speed N

Transmitter to Simulate 1900 MWT

Encoder to Simulate 0-30M

Return Temp Y

Temp To Simulate C

Offset Temp by 100 Y

Low Battery Indication HwIn1

Max Integer Value 9999

Minimum Level 0

Maximum Level 30.0

Minimum Temperature 0

Maximum Temperature 250

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Configuration Tank Gauge Transmitter

3.5.5 Imperial Fractional 1800 Series Transmitter Quick Setup

The Imperial fractional 1800 quick setup selection establishes the same default parameters as the Imperial Fractional 1900 quick setup with the exception that the sensor to emulate parameter is the 1800 MWT.

3.5.6 Imperial Decimal 1800 Series Transmitter Quick Setup

The Imperial decimal 1800 quick setup selection establishes the same default parameters as the Imperial decimal 1900 quick setup with the exception that the sensor to emulate parameter is the 1800 MWT.

3.5.7 0-20 Meters 1800 Series Transmitter Quick Setup

The 0-20 meters 1900 quick setup selection establishes the same default parameters as the 0-20 meters 1900 quick setup with the exception that the sensor to emulate parameter is the 1800 MWT.

3.5.8 0-30 Meters 1800 Series Transmitter Quick Setup

The 0-30 meters 1800 quick setup selection establishes the same default parameters as the 0-30 meters 1900 quick setup with the exception that the sensor to emulate parameter is the 1800 MWT.

24 Installation and Operations Manual

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4000 Configuration

3.5.9 Imperial Modbus Quick Setup Defaults

General Configuration

Level Units FT-IN-16th

Temp Units F

Level Sensor Forward

Damping 0

Temp Sensor Copper RTD

Manual Temperature

Critical High Level 80-0-0

Advisory High Level 80-0-0

Advisory Low Level 0

Critical Low Level 0

Level Deadband 0-1-0

Critical High Temp 500

Advisory High Temp 500

Advisory Low Temp 0

Critical Low Temp 0

Temp Deadband 1

Host Configuration

Type Modbus

Address 254

Baud 9600

Parity Odd

Stop Bits 1

Max Integer Value 9999

Minimum Level 0

Maximum Level 80-0-0

Minimum Temperature 0

Maximum Temperature 500

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Configuration Tank Gauge Transmitter

3.5.10 Metric Modbus Quick Setup Defaults

General Configuration

Level Units Meters

Temp Units C

Level Sensor Forward

Damping 0

Temp Sensor Platinum RTD

Manual Temperature 0.0

Critical High Level 20.0

Advisory High Level 20.0

Advisory Low Level 0

Critical Low Level 0

Level Deadband 0.03

Critical High Temp 250.0

Advisory High Temp 250.0

Advisory Low Temp 0

Critical Low Temp 0

Temp Deadband 1

Host Configuration

Type Modbus

Address 254

Baud 9600

Parity Odd

Stop Bits 1

Max Integer Value 9999

Minimum Level 0

Maximum Level 20.0

Minimum Temperature 0

Maximum Temperature 250.0

26 Installation and Operations Manual

Page 37

4000 Maintenance and Troubleshooting

4 Maintenance and Troubleshooting

4.1 Maintenance

The Varec Model 4000 Advanced Technology Transmitter (ATT) is designed and manufactured to provide accurate and reliable operation without a requirement for regularly scheduled maintenance.

Due to the modular construction of the ATT, necessary repairs can be quickly and safely accomplished.

Caution! When performing service or repair of any kind on the ATT , follow all instructions relative to power on/off requirements.

It is recommended that all necessary repairs be performed by a factory trained service engineer.

4.2 Battery Replacement

The ATT contains a battery module to maintain incremental count information during power outages. The battery shelf life is ten years and active life is 10 days. The ATT monitors the battery voltage and will indicate a low battery status to the host computer. The battery status can also be checked using the Handheld Terminal under the Summary Menu.

The ATT may indicate a low battery condition for several reasons:

• A brand new unit is shipped with the battery turned off.

• The battery is really low or bad.

• Someone has actually turned the battery off from the host computer or via the Handheld Terminal if an extended

power outage was anticipated.

• The ATT may have automatically turned its battery off. This occurs to preserve the battery if a power outage

occurs for more than a 24 hour period.

Using a Handheld Terminal get into the Alter Mode of operation. Check if the battery is really bad by calibrating the level. This turns on the battery circuitry automatically. Perform an Exit and Save and log back in using the Display Mode. The Summary Menu indicates the status of the battery as tested by the ATT.

Caution! Power to the ATT must be off before attempting to replace the battery. Do not apply power to the ATT until battery

replacement is complete and all covers have been replaced.

If the battery is still bad, perform the following to replace it:

1. Turn off all power to the ATT and remove the electronics' cover.

2. Locate the two covered batteries marked BT1 and BT2.

3. Slide off the battery cover.

4. Remove by sliding the batteries to the side and not straight out.

5. Replace with new batteries and replace battery cover.

6. Replace the ATT's cover

7. Turn the power to ATT back on.

8. Calibrate the level.

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Maintenance and Troubleshooting Tank Gauge Transmitter

4.3 Troubleshooting

The ATT has provisions for hardware alarm inputs, software generated setpoint alarms, and other alarm conditions.

Alarm and error status conditions are available to the Model 1200, to the host Computer, and to the optional ATT display. When in the Model 1200 display mode, the Diagnostic Status Menu displays only active alarm and error status conditions. General status conditions such as HW IN 1 are always displayed.

4.3.1 ATT Error Status Conditions

Error Message Description

BAD COMM BOARD The communication board did not pass the loopback test. See

BAD CPU BOARD RAM, EPROM, or EEPROM has failed.

BAD EEPROM CHECKSUM The EEPROM configuration data did not match the EEPROM

BAD EEPROM The value written to EEPROM memory did not match the value

BAD EPROM The program EPROMs have failed the EPROM test. This is a

BAD LEVEL The level input is invalid.

BAD RAM The RAM has failed the RAM test. This is a critical alarm.

BAD RTD RESISTANCE The ATT detected an invalid RTD resistance. Usually due to an

BAD TEMP The ATT detected an invalid temperature. Usually due to an

CALC ERROR Calculation overflow or divide by zero error.

CONFIG ERROR See the ATT configuration error checking in this section.

the description of the host communication loop-back tests.

stored checksum. Examine all configuration parameters, make any changes, and then use the "EXIT AND SAVE" option under the Main Menu.

read back from EEPROM memory. This is a critical alarm. Contact the factory.

critical alarm. Contact the factory.

Contact the factory.

open or shorted RTD input.

RTD failure.

LOW BATTERY The battery used to maintain the encoder circuitry has a low

NO CALC ERROR The ATT can no longer perform calculation. See information

OFFLINE MODE A Model 1200 is connected to the ATT at tank side. No ATTI

RTD UNCOVERED The Resistive Temperature Device (RTD) sensor is uncovered.

28 Installation and Operations Manual

voltage.

under the Stop Calculations Conditions section.

Bus sensor communication is active.

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4000 Maintenance and Troubleshooting

4.4 ATT Status Conditions

The ATT provides the following general status condition.

Status Condition Description

FIELD CONFIG MODIFIED

Set when the configuration is modified from the Model

1200. This status condition will only be available to the host computer and will not appear on the Model 1200.

4.5 A TT Configuration Error Checking

The ATT performs extensive integrity checking on the configuration data before it uses it for calculations. If a configuration error is detected, the ATT will generate a CONFIG ERROR status. The status is displayed on the local display, available to the Model 1200 via the Diagnostic/Status Menu, and available to the host computer. To help isolate the type configuration error, the operator can look at CFG ERROR TYPE item under the Diagnostic/Status Menu.

The following are the type of configuration errors and what causes them. The word 'Invalid' implies that the ATT was expecting one of a certain set of values to be assigned to a particular configuration option. This may have been caused by a sudden power outage, a failure in the EEPROM memory, or an invalid configuration received from a host computer.

Error Message Description

SCALING VAL

ALM SP

Check the level and temperature scaling values under the Host Comm Menu. The ATT insures that the minimum value is smaller than the maximum value.

Check the four level and four temperature alarm setpoints under the Config Menu. The ATT insures that the critical high setpoint is higher than the advisory high, the advisory high is higher than the advisory low, and the advisory low is higher than the critical low.

ALM DBAND

SENS CFG

Check the level and temperature deadbands under the Config Menu. The ATT insures that they are a positive value.

Check the Level Type and Temperature Type under the Config Menu. The ATT insures that they have valid values.

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Maintenance and Troubleshooting Tank Gauge Transmitter

4.6 Model 1200 Error Messages

The following error messages can be encountered while using the Model 1200.

Error Message Description

INVALID ANSWER

The operator was expected to enter either a 'Y' for yes or an 'N' for no and something different was entered.

INVALID FLOAT The operator entered an invalid floating point number. The

INVALID INPUT

proper format for floating point entry is

[spaces][sign]number['.'][number]['E'][sign][number]

where the fields surrounded by brackets([]) are optional. Leading spaces are permitted, however spaces within the number are not allowed. A maximum number of 15 characters is allowed. The exponent (value after 'E') cannot be larger than 30 nor less than -30.

The operator was given a choice of two different characters to enter and something else was entered.

INVALID NUMBER

NEGATIVE NUMBER

The operator entered an invalid number.

The operator entered a negative number when asked for a positive float number.

NOT ALTERABLE

The operator attempted to alter a Command, Informational, or Menu Item using the F3 (alter) key.

NOT IN ALTER MODE

The operator attempted to alter a Configuration Item using the F3 (alter) key while in the Display Mode.

TOO MANY CHARACTERS

The operator attempted to enter more than the allowed number of characters.

NUMBER TOO LARGE

The operator entered a number that is beyond the limits of a particular Configuration Item.

4.7 Host Communication Loopback Tests

Communications between a host computer and several field devices, such as the ATT, usually occurs on a single set of wires. Each device is individually addressable by the host computer.

The ATT contains special circuitry that reduces the chance of one ATT shorting the host communication lines. The circuitry allows the ATT to disconnect itself from the communication line and perform a loop-back test.

The test is performed automatically on power-up. It is also performed periodically if communication is no longer detected from the host computer.

If the ATT fails its local loop-back test, it will generate a 'Bad Comm Board' status and disconnect itself from the host communication lines. It will remain disconnected until it can pass its internal loop-back test.

30 Installation and Operations Manual

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4000 Specifications

5 Specifications

5.1 Specifications and Physical Characteristics

The following specifications apply to the Varec Model 4000 Advanced Technology Transmitter assembly over the operating temperature range.

5.1.1 Environmental

Item Specification

Temperature -40

Humidity -0 to 95% (non-condensing)

Transient Lightning Meets ANSII/IEEE C62.41

EMI Meets SAMA 33.1C

Vibration Shock Meets SAMA PMC 31.1

C to +85 oC (operating)

5.1.2 Physical

Item Specification

Housing Aluminum NEMA 4X, NEMA 7

Bolts Plated carbon steel per ASTM A449, Grade 2

Paint Epoxy-polyester

Dimensions 190.5 mm (7.5") diameter x 203.2 mm (8.0")

Net Weight 1.8 kg (4 LB)

Shipping Weight 3.6 kg (8 LB)

deep

5.1.3 Input Power

Item Specification

4000 M4FMO 48 - 65 VDC

4000 GMFMO 24 - 65 VDC

4000 48 FMO 24 - 65 VDC

4000 TIFMO 60 - 65 VAC

4000 GEFMO 45 - 55 VAC

4000 LJFMO 48 - 65 VDC

4000 MXFMO 48 - 65 VDC

4000 WBFMO 48 - 65 VDC

5 mA typical at 48 VDC 250 mW, Nominal

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Specifications Tank Gauge Transmitter

5.1.4 Level Measurement

Item Description

Resolution 0.04 in (1.0 mm)

Counter Level Range +/-128 ft (39 M)

Count Verification Check Disk

Level Data Type Absolute with Calibrated Level

Calibration Level Software Configured

Units of Measure Software Configured

Direction of Rotation Software Configured

Rotational Speed 1000 RPM Maximum

Gear Ratio 1:1 - No Gears

Communications Check Depends on communication system

Count Error Status Flag to System

Battery Low Status Flag to System

Battery Operation 336 Hours (with automatic shut-off after 24)

Battery Shelf Life 10 Years

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4000 Specifications

5.2 Safety Agency Approvals

5.2.1 Explosion Proof

The HART Level Encoder is designed to meet the following safety agency approval requirements for explosion proof installations:

Agency Acronym Agency Requirement

(FM) Factory Manual Approval StandardClass

3600, 3615, 810

(CSA) Canadian Standards Association Standard C22.2No. 0.0, 0.2,

(BASEEFA) CENELEC CENELEC StandardEN50014,

(UK) British StandardBS5501, Part

5.2.2 Intrinsic Safety

0.4, 0.5, 14, 30, 94, 142

EN50018

1, 5

The ATT is not an intrinsically safe device and must not be opened or wired while power is applied.

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Specifications Tank Gauge Transmitter

5.3 Major System Assemblies and Components

The major assemblies and components for the Model 4000 are identified in the following table and illustrated in Figure 5-1.

Item Assembly/Component Part Number

1 Shaft/Disk Assembly 06-09478

2 Sensor Assembly 08-09220

3 CPU Assembly 08-10671

4 Batteries, quantity 2 P117-01-004

5 Terminal Board Assembly 08-10702

6 GPE Terminal Board GPE-08-11515

7 Mark/Space Communications Module 08-10674

8 EIA-485 Communications Module 08-10677

9 Mark Space Matrix 08-10680

10 Whessoe Bus GPE Communications 08-10683

11 TIWAY Communications 08-10828

12 L&J Tankway Communications 08-10909

5 -

Figure 5-1: ATT Major Assemblies

34 Installation and Operations Manual

Page 45

4000 Order Codes

6 Order Codes

10 Communications

20 Approvals

30 Mounting

N4000 - Complete product designation

GE GPE Loop Communication MX Mark Space Matrix (1600/1700) TI TIWAY Communication WB Whessoe Bus Current Loop (1315) GM GSI Type MODBUS

CS CSA Cl.I Haz. Loc. (CAN/CSA C22.2,No. 30-M1986) FM FM Cl.I Gr. C,D; Cl.II Gr. E, F,G Cl.II Haz. Loc. (ETL 557067) AT DEMKO 04 ATEX 0327020 EEx d II B

0 Mounting 2500 ATG Series 1 L&J (Shand & Jurs) 92513, 92514, 92020, 92030 2 Whessoe 2006, 2026, 2036 and L&J (Shand & Jurs) 92006 3 Adapter for Sakura LT-101

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Order Codes Tank Gauge Transmitter

36 Installation and Operations Manual

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4000 Theory of Operation

7 Theory of Operation

7.1 Overview

The Advanced Technology Transmitter (ATT) represents a flexible system for use in liquid level measurement and/or other measurement applications.

The Advanced Technology Transmitter (ATT) collects measurement information from compatible devices and transmits this information over a field communications bus.

Check disk

Board

4 slots

Dual

Optical

Sensors

Conditioning

Increment

Detector

Logic

Signal

Single

16-Bit Binary

Up-Down Counter

Shielded Counter Section

Batteries

3 Volt Lithium

cells

Power

Switching

Circuits

Battery and Power

Monitor

Check Disk Signal

Power-

Isolation

Down

LED Power

Count

Plug-In Communications Board

Current

Controlled

Switching

Power

Supply

I/O

Ports

Interface Module

Assembly

Mark/Space

EIA-485

TIWAY

CPU Board

8031

Micro-

Processor

64 K

EPROM

2 K

RAM

Interface

Host

HART Bus

Interface

Circuit

HART

Modem

L&J Tankway Whessoe Bus Current loop Mark Space Matrix GPE Current loop

To ATTI

Bus

and Handheld Interface

Increment disk

128 slots

Shaft Input connected to

Model 2500

Sensor

Figure 7-1: ATT Block Diagram Table

7.2 CPU Board

The ATT uses the Phillips 80CL31 CPU with 64K of ROM and 8K of RAM.

The microprocessor assembly contains the CPU, power supply, and interfaces necessary to manage operation. The power conditioning circuitry also detects a battery low condition.

The CPU monitors the count maintained in a 16-bit register. The register stores pulse information from the sensor assembly. A ch eck disk pulse fro m the sensor a ssembly is us ed to verify the co unt at 1/4 of a disk revolut ion. The CPU maintains an absolute level measurement based on the level calibration count provided by the ATT and the count provided by the count register. Circuitry is provided to monitor the health of the back-up battery. When the battery voltage indicates the battery is near the end of its life, the CPU transmits a battery low indication to the ATT.

The power supply converts input power from the ATTI bus into the voltages necessary for normal encoder operation. The power supply limits input current from the ATTI bus to 8 mA.

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Theory of Operation Tank Gauge Transmitter

7.3 Status Inputs and Outputs

Status inputs and outputs are accomplished via a separate I/O Module. The ATT will communicate with the Module via the ATTI port. The state of the inputs will be mapped into Modbus registers to allow a host computer to read them. Control of status outputs will also be available to a host via Modbus registers. This unit is currently under development.

7.4 ATTI Communications Port

The ATTI Communication Port is a HART device compatible port. However, it does not power HART devices and is not designed to be intrinsically safe. It is used to communicate with the 1200 Hand Held Terminal for configuration. In the future it will support digital I/O extensions to the ATT including, 4120 Multi-Element Temperature Transmitter and 4040 Tankside display

7.5 Host Communications Interfaces

The ATT supports a plug-in host communication interface module. The following host communication modules are supported in the initial release of the ATT.

• EIA485 Modbus

• Mark/Space

• GPE Loop Communications

• TIWAY Communications

• L&J Tankway Communications

• Varec Mark Space Matrix

• GSI Modbus

7.6 Level Measurement

The HART Level Encoder utilizes a proprietary incremental count technique for determining liquid level. Two code disks are provided in the encoder with each disk containing a number of slots. Optical sensors for each disk detect disk rotation by sensing the passing of these slots. The primary disk contains 128 slots and is used to calculate the actual liquid level. The secondary or check disk contains only four slots and is used to verify or check the level from the primary disk. The count obtained from these sensors is stored in encoder memory.

7.6.1 Back-up Battery

The encoder's back-up battery provides continuous operation during power outages. The battery is non-rechargeable with a continuous operating lifetime of 10 days or more and a shelf life of ten years. To preserve the battery life, automatic battery shut down occurs after 24 hours of continuous power outage. The encoder monitors the voltage of the back-up battery and provides a battery low warning to the host in the event the battery needs replacement or has been turned shutdown due to an extended power outage.

7.6.2 Damping

The ATT implements a damping scheme to stabilize the level and temperature in turbulent tanks. The amount of damping is specified by a damping value in the 'DAMPING' parameter under the Config Menu. This parameter can be entered via the Model 1200 using the Alter menu.

A damping value of 0 to 16 can be specified. A damping value of 0 implies no damping. A damping value of 16 implies that level and temperature is averaged over 16 readings.

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4000 Theory of Operation

7.7 Encoder Battery Backup

The ATT includes battery backup for the encoder. This allows level to be maintained across a power failure. Several consideration are made to protect the battery from being fully discharged.

1. The battery must be physically enabled by the microprocessor. This allows the battery to be shipped connected without being discharged.

2. Service personnel can turn the battery off. This will allow the battery to be disabled when a tank or a transmitter is to be taken out of service for an extended period of time.

3. On-board circuitry limits the battery backup time to 24 hours. This allows battery life to be extended even if service personnel forget to disable the battery during extended power outage conditions.

The battery is automatically turned on when the ATT is calibrated with a given level.

7.8 Temperature Measurement

The ATT measures temperature directly using a high accuracy 16 bit analog to digital converter. Temperature inputs can be either a 3-wire Copper or Platinum RTD. Optionally the temperature can be manually entered. The 4120 MultiElement Temperature transmitter can be used as a replacement to a spot temperature bulb (RTD).

7.9 Host Communication

The Modbus host interface permits the ATT to directly communicate with any distributed control system utilizing the Gould Modbus protocol. The Modbus protocol defines two data formats, ASCII and RTU. The RTU format specifies that all data is in binary. The ASCII format specifies that all data is in ASCII (producing messages twice as long as RTU format messages). The ATT only supports the RTU message format.

The Modbus protocol permits a host computer to view field devices as having analog input registers, analog output registers, digital input registers, and digital output registers. Measured parameters, configuration parameters, and status conditions are mapped to Modbus analog and digital registers.

A non-standard Modbus floating point register extension has been defined for use by the ATT. This format extension permits floating point data to be directly read from and written to any Modbus device. The IEEE 754 standard floating point format is used. Each floating point register consists of four bytes.

To provide compatibility with future enhancements, data written to undefined registers are accepted and ignored. Data read from undefined registers returns a value of zero (0).

The supported Modbus functions and exceptions are indicated in the following tables.

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Theory of Operation Tank Gauge Transmitter

Function Number Function

01 Read Digital Outputs

02 Read Digital Inputs

03 Read Analog Output Registers

04 Read Analog Input Registers

05 Write Single Digital Output

06 Write Single Analog Output Register

08 Loopback Test

15 Write Multiple Digital Outputs

16 Write Multiple Analog Output Registers

65 Read Floating Point Registers

66 Write Floating Point Registers

Table 7-1: Modbus Functions

Number Exception

01 Illegal Function

02 Illegal Address

03 Illegal Data

04 Busy

Table 7-2: Modbus Exception Responses

7.10 Mark/Space Host Interface

The Mark/Space interface provides compatibility with existing Mark/Space data highways. The interface operates in one of two modes.

• Transmitter Emulation Mode

• Varec 1800 Transmitter Emulation

• Varec 1900 Transmitter Emulation

• Mark/Space Modbus Communication Mode

When operating in the 1800 or 1900 emulation mode, the ATT is compatible with all existing Varec field interfaces such as the Tank Polling Unit (TSU) or RTU 8130.

The ATT automatically determines if it is being polled as an 1800/1900 transmitter. When polled, the ATT will respond based on the configured emulation mode. The ATT can be configured to support the following encoding formats:

• Imperial Fractional

• Imperial Decimal

• Metric, 0-20 meter

• Metric, 0-30 meter

When emulating an 1800 or 1900, battery low status can be reported as one of the dry-contact inputs or as an invalid level.

Note! The ATT will accept but ignore the Raise/Lower Displacer commands.

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4000 Theory of Operation

7.11 Modbus Support over Mark/Space Host Interface

The ATT permits Modbus communications over the Mark/Space data highway. The Modbus request message is placed into a Mark/Space message frame. The ATT processes the request message and places the Modbus reply in a Mark/ Space reply frame.

This option is only available with systems using the Model 6840 Tank Polling Unit.

7.12 Compatibility with Varec Tank Polling Unit

The Mark/Space communications provided by the ATT are compatible with the Varec Tank Polling Unit (TPU). This permits the ATT to be multi-dropped on the same Mark/Space data highway as the Varec 1800, Varec 1900, and MFT/ HIU devices.

If the EIA485 communications interface is installed in the ATT, it can be multi-dropped on an EIA485 data highway, RTU 8130 along with any Modbus compatible device, including the Model 6850 Field Interface Converter.

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Theory of Operation Tank Gauge Transmitter

42 Installation and Operations Manual

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4000 ATT Family of Products

8 ATT Family of Products

The ATT product family consists of the 4000 ATT, the Model 4040 Display Unit, and the Model 4050 Digital Input/ Output Unit.

Model 4000 ATT

Model 4000

mounted to Float Gauge

24-65 Vdc for EIA-485

48-65 Vdc for Mark/Space

65 Vac for TIWAY

8-65 Vac for Whessoe Bus

Model 4050

Connection to host

computer system via:

4-Wire Mark/Space

Matrix Mark/Space

TIWAY

Whessoe Bus

GPE

L&J

Handheld Interface

connects to any unit

for system configuration

Connection to spot

temperature bulb

Three wire ATTI Bus

Digital I/O Unit

Connection to

four digital inputs an

four digital outputs

Model 4040

Display Unit

Figure 8-1: ATT Family of Products

8.1 Model 4040 Display Unit

The Model 4040 is a four line LCD display unit. It operates connected to and is powered from the ATTI bus. The Unit is mounted in a round explosion proof junction box with a window. Two 3/4-inch conduit entries are available.

Configuration is performed with the handheld interface. The handheld interface can be connected to any point on the ATTI bus to communicate with the Model 4040. The user may select any of the following parameters for display on each of the three lines.

• Level (default)

• Temperature (RTD - default, or Average)

• Status (default)

• Digital I/O Unit 4, 5 or 6

• Input 1-2-3-4

• Output 1-2-3-4

• Analog I/O Unit 7, 8 or 9

• Input 1-2-3-4

• Output 1-2-3-4

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ATT Family of Products Tank Gauge Transmitter

8.2 Model 4050 Digital Input/Output Unit

The Model 4050 is a digital I/O unit. It includes four digital contact closure outputs and four digital inputs. It operates connected to and is powered from the ATTI bus. The unit is mounted in a round explosion proof junction box. Three 3/4-inch conduit entries are available.

• Primarily configured by jumpers. Three sets of jumpers are used.

• Unit address: 4 jumpers for range 0-15. Digital I/O units normally use address 4,5 or 6.

• Active state jumper for each digital output. Jumper determines if contact is N. O. or N. C.

• Default power condition for each digital output. Jumper determines if contact is open or closed when no power is

applied.

8.2.1 Digital Outputs

The use of the digital outputs is configured within the ATT using the handheld interface. Digital outputs 1 - 4 can be configured as follows:

1. Set output as level switch:

• Set for low or high closure.

• Set level to actuate.

2. Set output for Modbus command to write.

8.2.2 Digital Inputs

Digital inputs 1 - 4, can each be read with a Modbus command.

8.2.3 Relay Specifications

The latching relays will switch 110 VAC at 1 A or 24 VDC at 2 A. The unit does not support 220/230 VAC.

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4000 Modbus Implementation

9 Modbus Implementation

9.1 Introduction

This protocol guide explains the operation of the Modbus protocol as described in the following Modicon document:

PI-MBUS-300 Rev B (1985) implemented in the Varec Model 4000 Advanced Technology Transmitter (ATT).

9.2 Implementation

The implementation of the Modbus protocol for the ATT provides a standard form of digital communications. An effort has been made to parallel current implementations to the greatest extent possible, so that the ATT communicates with existing Modbus masters.

Check compatibility carefully to ensure that the ATT is properly configured for the data format expected by the host computer. Exceptions made because of the unique requirements of the ATT application have been noted. This is no guarantee, however, that the interpretation made here will be the same as that followed by the Modbus master.

The ATT implementation of the Modbus protocol provides for the passing of measured and calculated variables, configuration information, and diagnostics in data registers. Data is sent in these registers as floating-point values, integer values, numeric codes related to configuration lists, status summary words (packed bits), or individual status flags (single bits).

One master and up to 31 ATTs may be multi-dropped on a single EIA485 communication bus.

The Modbus functions implemented in the ATT are listed in Figure 9-1 on page 46.

9.3 Configuration

The Modbus port on the ATT must be configured to establish communications. The Model 1200 Handheld Interface allows the user to set the ATT Modbus port to match the Modbus master.

ATT addresses provide unique identification for the host. The ATT address is configurable through the Model 1200. This address may range from 1 to 254 and must be unique. Each ATT only responds when a query has been sent to its unique address by the host.

The Modbus protocol supports two modes of transmission, Remote Terminal Unit (RTU) or ASCII (American Standard Code for Information Interchange). The choice between these two modes is dependent on the preference of the host. RTU is often the preferred protocol because of its improved error detection capabilities and higher throughput. ASCII mode uses ASCII printable characters to represent hexadecimal values. This mode of transmission requires almost twice as many characters to pass information as does the RTU transmission mode. The ATT only supports the RTU mode of communications.

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Modbus Implementation Tank Gauge Transmitter

Function

Code

01 Read Bits Read output status

02 Read Bits Read input status

03 Read Integer, Code, Status word,

04 Read Integer, Code, Status word,

05 Write Bits Force single output status

06 Write Integer, Code, Status word Preset single register

08 n/a Repeat of Loopback Message Loopback test

15 Write Bits Force multiple outputs

16 Write Integer, Code, Status word,

65 Read Floating point Read floating point registers

66 Write Floating point Write floating point registers

Function Information Type Modbus Nomenclature

Read output registers

Floating point

Read input registers

Floating point

Preset multiple registers

Floating point

Table 9-1: Modbus Functions

Note! Exception: Because the A TT does not distinguish between inputs and outputs, function codes 01 and 02 as they apply

to bits, and function codes 03 and 04 as they apply to numeric values refer to the same data registers. For example, either function code 03 or function 04 can be used to read the integer form of the true mass variable at data address

0053.

Configuration Item Valid Entries Modbus

Modbus Address 1 to 254 No Yes

Maximum Integer Size Whole number (0 to 65,534) Yes Yes

Integer Scaling Factors Floating point number Yes Yes

Unit Selection Coding list Yes Yes

Baud Rate 300, 600, 1200, 2400,

4800, 9600

Number of Stop Bits 1 or 2 No Yes

Parity Odd, Even, None No Yes

Configurable

No Yes

Model 1200

Configurable

Table 9-2: Modbus Configuration Information

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4000 Modbus Implementation

9.4 Functions and Data Formats

The Modbus data in the ATT is arranged in integer registers, floating point registers, and status bits. The assignments for these registers are found at the end of this appendix.

Function codes 03, 04, 06, and 16 are used with integer registers.

Because of the multiple Modbus hosts available today, the ATT supports two floating-point data formats: a two 16bit register format and a one 32-bit register format. These two formats provide maximum system flexibility. In the two 16-bit registers format, function codes 03 and 04 are used to read floating-point registers while function code 16 is used to write floating-point registers. In the one 32-bit register format, function code 6 5 i s u s e d t o read floatingpoint registers, while function code 66 is used to write floating-point registers.

Function codes 01, 02, 05, and 15 are used with status bits.

A complete description of all the preceding commands, except floating point, can be found in the Modicon Modbus Protocol Reference Guide, document number PI-MBUS-300 Rev B.

9.5 Integer Registers

Integer registers are the most commonly used type of Modbus data and are supported by most Modbus hosts. In the ATT implementation, the Modbus registers are arranged in one of the following four formats:

• Integer Data - a scaled number from 0 to the maximum Modbus integer

• Character Data - 2 ASCII characters per 16-bit register (ex. date, password)

• Coded Data - Multiple choice configuration data chosen from a coded list

• Packed Bit Data - Register form of 16 packed single bits

The integer, character, and coded data registers contain all of the information needed to configure and read process data. Any integer register may be read with function code 03 or function code 04. These same registers may be written one at a time with function code 06 or multiple registers can be written with function code 16.

For future compatibility, the ATT accepts reads and writes to reserved registers. Writes to reserved registers have no effect. Reads from reserved registers return a zero (0).

Term Definition

Address User-assigned address of the slave device

Function Code Function the slave is to perform

Start Register (H) High-order data address byte of the number of registers to read

Start Register (L) Low-order data address byte of the first register to read or write

Number of Registers (H) High-order byte of the number of registers to read or write

Number of Registers (L) Low-order byte of the number of registers to read or write

or write

Byte Count Number of data bytes

Data MSB Data register's most significant byte

Data LSB Data register's least significant byte

Status Bit (H) High-order data address byte of the first bit to read or write

Status Bit (L) Low-order data address byte of the first bit to read or write

Error Check Message checksum CRC (Cyclical Redundancy Check)

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Modbus Implementation Tank Gauge Transmitter

Note! In all of the following communication examples, the error check value is dependent upon the mode of transmission.

9.5.1 Integer Data

The integer data is a whole number between 0 and the maximum Modbus integer (inclusive). The maximum Modbus integer is a user-configurable variable that is a whole number between 0 and 65,535 (inclusive). The integer data must also be scaled for each data type by entering the desired units, a minimum, and a maximum value. In order for the integer value to be correctly interpreted, these scaling factors must match the format expected by the host system. Scaling of the integer parameters is accomplished through floating-point registers or by using the Model 1200 Handheld Interface.

The following communication example shows the request for one register starting at register 0 (0000 Hex).

For the following example, assume:

• minimum = 1 meter

• maximum = 15 meters

• maximum Modbus integer = 65,534

Host Request

Address Function

Code

01 03 00 00 00 01 XX

ATT Response

Address Function

code

01 03 02 41 24 XX

Start RegHStart RegL# of Reg

Byte Count

Data

MSB

Data

LSB

# of Reg

Error

Check

Error

Check

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4000 Modbus Implementation

9.5.2 Integer Data

• Hexadecimal representation

• 4124Decimal equivalent: 16,676

The data returned for data address 56 is 16,676 (4124 Hex). This value must be scaled using the following formula to give it meaning.

If a variable goes out-of-bounds (outside the minimum or maximum scale points), a value equal to the maximum Modbus integer + 1 is returned. Writing to dynamically calculated parameters has no effect on those parameters.

9.5.3 Character Data

Character data, such as software version, are returned in registers in ASCII data format. Each Modbus register represents two ASCII characters.

The following communication example shows the character data "ATT-" read from the ATT.

Host Request

Address Function

Code

01 03 00 1E 00 02 XX

ATT Response

Address Function

code

01 03 04 41 54 54 2D XX

• Hexadecimal representation 41 54 54 2D

• ASCII representation: ATT-

Start RegHStart RegL# of RegH# of RegLError

Check

Byte Count

Data

MSB

Data

LSB

Data

MSB

Data

LSB

Error

Check

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Modbus Implementation Tank Gauge Transmitter

9.5.4 Coded Data

Coded data represents a table look-up value. Data written to these registers must be a valid table entry. Invalid data may cause a Configuration Error to occur. The following example shows coded data at data address 20 (0014 Hex) representing level units. The value 2 (0002 Hex) returned from the ATT corresponds to level units = FT-IN-16TH.

Host Request

Address Function

Code

01 03 00 14 00 01 XX

ATT Response

Address Function

code

01 03 02 00 02 XX

• Hexadecimal representation 0002 (decimal 2)

• Level unit table representation: FT-IN-16TH

Start RegHStart RegL# of Reg

Byte Count

Data

MSB

Data

LSB

# of Reg

Error

Check

Error

Check

9.5.5 Packed Bit Data

Packed bits represent 16 individual status bits packed into one register. The status bits have been packed this way for systems that prefer handling only register information. These bits may also be read or written individually using a bit command. The bits within the packed registers are grouped by data or function type. The following communication example of packed bits shows alarm status information at data address 5 (0005 Hex) returned by the ATT.

Host Request

Address Function

Code

01 03 00 05 00 01 XX

ATT Response

Address Function

code

01 03 02 00 01 XX

Note! Bit #0 is ON indicating a critical low level Alarm

Start RegHStart RegL# of Reg

Byte Count

Data

MSB

Data

LSB

# of Reg

Error

Check

Error

Check

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4000 Modbus Implementation

9.6 Floating-Point Registers

Although not part of the Modbus protocol specification, floating point numbers have been implemented using the IEEE 754 standard. Floating point numbers reduce the complexity required in scaling integer values and provide a means to transmit numbers used by the ATT that are not easily scaled (such as the scaling factors themselves).

9.6.1 Floating-Point Data

The ATT is capable of using a two 16-bit registers format and a one 32-bit register format. Examples and descriptions of both formats follow.

Note! Although this type of data does not require scaling, it is important that the measurement unit selected in the ATT be

the same as that expected by the host. In addition, where possible, data is available in both integer and floating-point formats.

9.6.2 The Two 16-bit Registers Format

Function code 03 or 04 is used to read floating-point registers in this format. Function code 16 is used to write floating-point registers in this format. An example of reading the temperature, register 102 ( 0066 Hex), in floatingpoint format from the ATT is shown as follows:

Host Request

Address Function

Code

01 03 00 66 00 02 XX

ATT Response

Address Function

code

01 03 04 42 C8 00 00 XX

Start RegHStart RegL# of RegH# of RegLError

Check

Byte Count

Data

MSB

Data

LSB

Data

MSB

Data

LSB

Error

Check

9.6.3 Floating Point Data

• Hexadecimal representation: 42 C8 00 00

• Decimal equivalent: 100.00

Floating-point registers that are defined as reserved have zero (0) as their only legal value. A write command to a reserved floating-point register is ignored.

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Modbus Implementation Tank Gauge Transmitter

9.6.4 The One 32-bit Register Format

Function code 65 (41 Hex) is used to read floating-point registers in this format. An example of a floating-point register read is shown below with the a temperature of 100.0 degrees is being read from register 1 (0001 Hex).

Host Request

Address Function

Code

01 41 00 01 00 01 XX

ATT Response

Address Function

code

01 41 00 01 42 C8 00 00 XX

Start Reg H

# of Reg H

Start RegL

# of Reg L

# of Reg H

Data

MSB

# of Reg L

Data Data Data

Error

Check

LSB

Error Check

9.6.5 Floating Point Data

• Hexadecimal representation: 42 C8 00 00

• Decimal equivalent: 100.00

Function code 66 (42 Hex) is used to write floating-point registers. An example of a floating-point register write is shown below with the value 100.0 being written into the Advisory High Temperature Alarm Setpoint, register 12 (000C Hex).

Host Request

Address Function

Code

01 42 00 0C 00 01 42

ATT Response

Address Function

code

01 03 02 41 XX

Start RegHStart RegL# of Reg

Data Data Data

C8 00 00 XX

# of Reg H# of Reg LError

Check

# of Reg

LSB

Data MSB

Error Check

9.6.6 Floating Point Data

• Hexadecimal representation: 42 C8 00 00

• Decimal equivalent: 100.00

Floating-point registers that are defined as reserved have zero (0) as their value. A write command to a reserved floating-point register will be ignored.

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4000 Modbus Implementation

9.7 Status Bits

In the ATT implementation, status bits contain alarms, commands, and status information. The state of a Modbus status bit is defined as either ON (true) or OFF (false). The ON state is represented by a "1". The status bits may be read with function code 1 or 2. They may be written one at a time with function code 5 or multiple bits may be written with function code 15. An example of a read message for bits 2 through 6 as returned by the ATT is shows as follows.

Host Request

Address Function

Code

01 02 00 02 00 04 XX

ATT Response

Address Function

code

01 02 01 12 XX

Start RegHStart RegL# of Reg

Byte Count

Data Error

9.7.1 Status Bit Data

Check

# of Reg

Error

Check

Binary representation 1 0010 (bits 6-2) Bit #2: High Advisory Alarm OFF Bit #3: High Critical Alarm ON Bit #4: Unauthorized Mass Movement OFF Bit #5: Standard Density Alarm OFF Bit #6: Critical Zone Alarm ON

9.8 Exception Responses

The exception responses returned by the ATT are listed below:

Exception Response Reason

01 Illegal Function Message is not allowed

02 Illegal Data Address Data address (bit or register) requested is not defined

03 Illegal Data Value Data value being written is out of range

04 Busy During power-up

In addition, messages that are received with a parity error, checksum error, or message format error will be ignored.

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9.9 Data Out of Range

When integer data calculated by the ATT is outside the minimum or maximum scale points or is otherwise out of range, the value returned is that of the maximum Modbus integer + 1. For example, if the maximum Modbus integer is 65,534 (as used in our previous examples) the "data out of range" value is 65,535. The "data out of range" convention does not apply to the status bits, packed status bits, character data, and coded data.

The following error conditions will also cause the ATT to return scaled integer values of maximum Modbus integer + 1.

• Off-line Mode

• Strap Error

• No CALC

• API Correction Error

• CALC Error

This permits a host to detect a serious failure without monitoring other ATT status bits.

9.10 Loopback Test

In accordance with the Modbus specification, function code 8 initiates a loopback test. The purpose of this test is to check the communication system. It does not affect the operation of the ATT. The ATT supports only diagnostic code

00. This is a request to return query data. Upon receiving a loopback message containing this code, the ATT will echo the message sent by the host. The entire message returned will be identical to the message transmitted by the host field-per-field. An example of a loopback message is as follows:

Host Request

Address Function

Code

01 08 00 02 F3 26 XX

ATT Response

Address Function

code

01 08 00 00 F3 26 XX

Code HO Code LO Data Data Error

Check

Code HO Code LO Data Data Error

Check

9.11 Hardware Implementation

The ATT uses a 2-Wire EIA485 hardware interface to communicate with the Modbus master. EIA485 is a high speed differential communications network which allows up to 32 devices to operate on one network. The ATT and Modbus master share a twisted pair of wires to communicate.

The communication distance EIA485 can reliably travel is dependent on baud rate (communication speed), wire quality, environmental noise, wiring configuration, and the number of multi-dropped ATTs. The recommended wire for EIA485 systems is 18-gauge or larger, shielded, twisted pairs. The shield should be earth grounded at the Modbus master (control system or computer end). The shield at the ATT should be open. The ATT- power line acts as a common reference tie to the Modbus master

Termination resistors of 120 Ohms are shown at each end of the communication bus to minimize reflections on the line. Termination resistors may not be necessary at baud rates of 9600 bits per second or slower. Pull-up and pulldown resistors are also shown at the Modbus master end of the cable. These resistors minimize the affects of noise when the lines are idle. Only one set of pull-up or pull-down resistors are required per twisted pair cable.

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9.12 Integer Register Map

0 Scaled Level

1 Scaled Temperature

2 Reserved

3 Reserved

4 Reserved

5 Bit Field AimStat

Bit Usage 0 CRIT LO LEVEL 1 ADV LO LEVEL 2 ADV HI LEVEL 3 CRIT HI LEVEL

4 CRIT LO TEMP 5 ADV LO TEMP 6 ADV HI TEMP 7 CRIT HI TEMP 8 HW IN 1 9 HW IN 2 10 ..15 RESERVED

6 Bit Field DiagStat

Bit Usage

0 BAD LEVEL

1 BAD TEMP

2 BAD EE

3 BAD EE CKSUM

4 BAD RAM

5 BAD EPROM

6 LOCAL MODS

7 NO CALC

8 CFG ERROR

9 CALC ERROR

10 BAD CPU BOARD

11 BAD COMM BOARD

12 LOW ENC BATT

13.15 RESERVED

7 Bit Field CmdsBit Usage

0 CANCEL ALT

1 CLR LOCAL MODS

2 RESTART

3 SAVE TO EE

4 RESERVED

5 CALIB LEVEL

6 ENC BATT OFF

7 QUICK SETUP

8.15 RESERVED

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Modbus Implementation Tank Gauge Transmitter

8 9

10 11 12 13 14 15 16 17 18 19

20 Code Level Units

21 Code Temp Units

22 Code Level Type

23 Code Temp Type

24 25 26 27

28 Code Quick Setup Option

Reserved

Code

Scaled Scaled Scaled Scaled Scaled Scaled Scaled Scaled Scaled Scaled

Scaled

Code Code

Scaled

A/D Noise Reject: Type 0 - 60Hz 1 - 50 Hz

Crit Low Level Setpoint

Adv Low Level Setpoint

Adv High Level Setpoint

Crit High Level Setpoint

Level Deadband

Crit Low Temp Setpoint

Adv Low Temp Setpoint

Adv High Temp Setpoint

Crit High Temp Setpoint

Temp Deadband

0 - METERS 1 - FEET 2 - FT-IN-16TH

0 - C 1 - F 2 - K

1 - FORWARD 2 - REVERSE

0 - NONE 1 - COPPER RTD 2 - PLATINUM RTD

Manual Temperature

Max Integer Value

Damping Value

Calibration Level

0 - NONE 1 - ENG FRAC 1800 2 - ENG DEC 1800 3 - 0 TO 20 M 1800 4 - 0 TO 30M 1800 5 - ENG FRAC 1900 6 - ENG DEC 1900 7 - 0 TO 20 M 1900 8 - 0 TO 30M 1900 9 - METRIC Modbus 10 - IMPERIAL Modbus

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29 30 31 32 33

34..99 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142

144...199 200 202 204 206 208 210

Reserved

ASCII ASCII ASCII ASCII

Reserved

Float Float

Float Reserved Float Reserved Float

Float

Float Reserved Float

Float

Reserved

Float

Float Reserved Float Reserved Float

Bit Field

Sw Ver[0-1] AT

Sw Ver[2-3] T-

Sw Ver[4-5]

Sw Ver[6-7]

Level

Temp

RTD Resist

Crit Low Level

Adv Low Level

Adv High Level

Crit High Level

Level Deadband

Crit Low Temp

Adv Low Temp

Adv High Temp

Crit High Level

Temp Deadband

Min Level

Max Level

Min Temp

Max Temp

Man Temp

Calib Level

Level

Temp

RTD Resist

AlmStat

211 Bit Field DiagStat

212 Reserved Reserved

213 214

215 Code Level Units

216 Code Temp Units

217 Reserved Reserved

218 219

220 Code Level Type

221 Code Temp Type

222 Reserved Reserved

Reserved Reserved

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Modbus Implementation Tank Gauge Transmitter

223 224 225 226

227 Reserved Reserved

228 229 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260

Reserved Reserved

Code Code

Reserved Reserved

Float Float Float Float Float Float Float Float Float Float Float Float Float Float

Reserved Float

Float

Damping Value

A/D Noise Reject: Type

Crit Low Level

Adv Low Level

Adv High Level

Crit High Level

Level Deadband

Crit Low Temp

Adv Low Temp

Adv High Temp

Crit High Level

Temp Deadband

Min Level

Max Level

Min Temp

Max Temp

Man Temp

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9.13 Floating Point Register Map

10 11

12 13

14 15

16 17

18 19

20 21

Level Temp

RTD Resist Reserved

Reserved Crit Low Level

Adv Low Level Adv High Level

Crit High Level Level Deadband

Crit Low Temp Adv Low Temp

Adv High Temp Crit High Level

Temp Deadband Min Level

Max Level Min Temp

Max Temp Reserved

Man Temp Calib Level

9.14 Status Bit Register Map

0..15 16..31

32..47 AlmStat

Diag Stat Cmds

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4000 Optional Interfaces

10 Optional Interfaces

Our intent with these optional interfaces is enabling the ATT to coexist along side older VAREC style and competitor gauging systems and transmitters. This allows the user upward migration to modern gauging systems such as the RS485 signal interface utilizing the MODBUS register set protocol. When ready to migrate to modern systems, a simple exchange of the ATT communications module is required.

10.1 4000TIFMO

This option is compatible along side TIWAY™ transmitters. Although the ATT can coexist along side all of the TYWAY™ transmitters, the communication option is restricted to the HDLC Link Level Protocol, utilizing IT111 primitives. The ATT is also compatible "user selectable" with an earlier version of the TYWAY™ protocol "CIM".

The ATT has user selectable configuration jumpers to apply 120-ohm termination in case maximum baud rates and wiring distances are implemented.

This ATT option is compatible to utilize the companion products Model 4040 Tank side Display and the Model 4050, 4 channel Digital Input and outputs.

10.2 4000GEFMO

This option is compatible along side GSI / L&J transmitters. Although the ATT can coexist along side any current loop mode transmitters, the communication option is restricted to the GPE Level Protocol format. This format utilizes what we refer to as short and long data responses regarding level, temperature, and status. Because of the nature of this protocol the temperature range of the RTD is limited to -200ºC to +200º C.

10.3 4000LJFMO

This option can co-exist with L&J Tankway™ Host gauging system and `transmitters. Basically it is a signal format similar to RS-232, however signal voltage levels are in the 0 to 35 VDC range. Basic user selectable baud rate, stop and parity bits. Transmitter address is selectable between 1 and 127; protocol is simple in nature of 2 bytes up and 2 bytes back. Response data consist of product level and temperature, encoder gray code and 2 status bits for error checking and data validity.

10.4 4000MXFMO

This option can co-exist along side VAREC style matrix transmitters. As implied a transmitter is selected actively by either the 48-volt or the common line in the matrix. When selected 3 milliseconds later the transmitter sends the level data over the Mark Space data lines. This is refereed to as hard wire logic, which occurs only once when selected, it is as if the transmitter is asleep only to wake up send data and go back to sleep. There are no communications parameters to select because only 1 transmitter can be triggered in the matrix at one given time.

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Optional Interfaces Tank Gauge Transmitter

10.5 4000WBFMO

This option can co-exist along side Whessoe Bus™ transmitters, the signal format is a current loop style transmission signal. Transmitter is user selectable between 1 and 127 with basic baud rates stop and parity bits. The protocol is referred to as Whessmatic 550, which was widely used by the UK for their Intelligent Tang gauging systems. The ATT meets and exceeds the requirements of the Whessmatic 550 format because of its redundant dual port capabilities, and the bipolar signal circuitry design. The advanced circuitry allows the ATT to communicate without error at 9600 baud through 2 data ports simultaneously. A typical transmitter using current loop signal format nominally communicates at 300 to 1200 baud at maximum.

10.6 4000GMFMO

Basically this is identical to the standard release of the 400048FMO, a MODBUS protocol device communicating over RS-485 data lines. GSI, a tank gauging systems manufacturer has re-mapped level and temperature integer registers to non-standard MODBUS locations. This version ATT allows it to co-exist along side GSI transmitters and gauging systems with response data as expected.

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4000

Glossary

Adv Hi Level Advisory High Level alarm set point. When the product level exceeds this point an advisory alarm will be generated.

Adv Hi Temp Advisory High Temperature alarm set point. When the product temperature exceeds this point an advisory alarm will

be generated.

Adv Lo Level Advisory Low Level alarm set point. When the product level drops below this point an advisory alarm will be generated.

Adv Lo Temp Advisory Low Temperature alarm set point. When the product temperature drops below this point an advisory alarm

will be generated.

Adv Rtd Level Advisory Resistive Temperature Device Level. Height of the RTD in the tank. An alarm is generated when the level goes

below this level (temperature measurements can no longer be made).

Advisory Alarms Process alarms intended to act as caution indicators providing users advanced warnings of unusual situations.

ATT Varec Model 4000 Advanced Technology Transmitter.

ATTI Bus Unpowered, non-intrinsically safe, HART compatible communication bus used on ATT.

Baud Rate A communications measure of serial data transmission rate typically in bits per second. Normal baud rates for RS-232

interfaces are 300, 1200, 2400, 4800, 9600, 19200. The higher the baud rate, the faster the data transfer occurs across the data line.

Comm Port Communication Port. An access point for data entry or exit.

Crit Hi Level Critical High Level alarm set point. When the product level exceeds this point a critical alarm is generated.

Crit Hi Temp Critical High Temperature alarm set point. When the product temperature exceeds this point a critical alarm is

generated.

Crit Lo Level Critical Low Level alarm set point. When the product level drops below this point a critical alarm is generated.

Crit Lo Temp Critical Low Temperature alarm set point. When the product temperature drops below this point a critical alarm is

generated.

Celsius. A unit of measure for temperature readings. 0

C is the freezing point for water, 100 oC is the boiling point

of water.

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Tank Gauge Transmitter

DBAND Deadband.

ft-in-16 Feet-inches-1/16 of an inch. Imperial fractional measurement.

oF Fahrenheit. A unit of measure for temperature readings. 0

water, 212

F is the boiling point of water.

C = 32 oF. A temperature of 32 oF is the freezing point of

Host A tank data acquisition system responsible for collecting and processing information from a number of subordinate

devices.

IEEE Institute of Electrical and Electronic Engineers. A trade organization that provides publications, educational

information, and standards that are widely used.

IEEE 754 A floating point data format.

oK Kelvin. A unit of measure for temperature readings typically applied to the measurement of liquefied gases. 0

273.16

K. The freezing point of water is 273.16 oK, the boiling point is 373.16 oK.

Level Dband Level Deadband. The band that a level alarm must clear before the alarm is reset.

Level Level of product in a tank.

Manual Temp A product temperature specified and entered by the user instead of being obtained from a sensor.

MHz Megahertz, also called megacycles. One million electronic cycles per second, a unit of electronic frequency.

Parity A setup parameter used with serial data communications.

RTD Resistive Temperature Device. A metal probe used to measure temperature.

Serial Ports A hardware interface used for serial data communications.

C =

Stop Bits A setup parameter for serial data communication.

Temp Dband Temperature Deadband. The band that a temperature alarm must clear before the alarm is reset.

Temp Temperature.

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TSU Tank Polling Unit. A Varec interface unit that allows a host computer to interface to Varec Mark/Space, Remote

Selector, IFU, and Matrix field interfaces.

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NOTES

Page 78

Your official representative

Your offical representative

www.varec.com

5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA

The names of actual companies and products mentioned herien may be the trademarks of their respective owners.

Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939

Varec, Inc.