Rosemount TankRadar Rex 3900 Series User guide

www.rosemount-tg.com
Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
Safety Manual For Use In Safety Instrumented Systems
Product Discontinued

Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
www.rosemount-tg.com
Safety Manual
Rosemount TankRadar Rex
First edition
Copyright © June 2007
Rosemount Tank Radar AB

Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
www.rosemount-tg.com
Copyright © June 2007
Rosemount TankRadar AB
Spare Parts
Any substitution of non-recognized spare parts may jeopardize
safety. Repair, e.g. substitution of components etc, may also
jeopardize safety and is under no circumstances allowed.
Rosemount TankRadar AB will not take any responsibility for
faults, accidents, etc caused by non-recognized spare parts or
any repair which is not made by Rosemount TankRadar AB.
WARNING
Do not open the Integrated Junction Box JBi
when the circuit is alive.

Safety Manual
308020EN, Edition 1
June 2007
i
Rosemount TankRadar Rex
Contents
Contents
1. SCOPE AND PURPOSE OF THE SAFETY MANUAL . . . . . . . . . . 1
2. REFERENCE DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. SCOPE OF THE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 PURPOSE OF THE PRODUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 ASSUMPTIONS AND RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 FUNCTIONAL SPECIFICATION OF THE SAFETY FUNCTIONS . . . . . . . 3
3.4 PARAMETERS RELATED TO SAFETY FUNCTIONS . . . . . . . . . . . . . . . . 7
3.5 HARDWARE AND SOFTWARE CONFIGURATION . . . . . . . . . . . . . . . . . 12
4. INSTALLATION AND CONFIGURATION. . . . . . . . . . . . . . . . . . 13
4.1 CONFIGURATION WITH ONE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 CONFIGURATION WHEN USING TWO RELAYS IN SERIES . . . . . . . . . 17
4.3 VERIFICATION OF THE SAFETY FUNCTION . . . . . . . . . . . . . . . . . . . . . 20
4.4 WRITE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5. PROOF TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 TRIGGERING THE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 HAND DIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 VERIFICATION OF THE RELAY FUNCTION . . . . . . . . . . . . . . . . . . . . . . 23
5.4 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6. TERMS AND DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Appendix FMEDA and Proven-in-use Assessment . . . . . . .27

Safety Manual
308020EN, Edition 1
June 2007
ii
Rosemount TankRadar Rex
Contents

1
Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
Chapter 1 Scope and Purpose of the
Safety Manual
1. Scope and Purpose of the Safety Manual
The purpose of the safety manual is to document all the
information, relating to TankRadar Rex 3900 Series, which is
required to enable the integration of TankRadar Rex into a safety-
related system, in compliance with the requirements of IEC
61508.

2
Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
Chapter 2 Reference Documents
2. Reference Documents
• IEC 61508
• IEC 61511
• Rosemount TankRadar Rex Installation Manual,
Ref. no. 308014EN
• Rosemount TankRadar Rex Service Manual,
Ref. no. 308012EN
• Rosemount TankRadar Rex Special Safety Instruction,
Ref. no. 308016E
• TankMaster WinSetup User’s Guide, Ref. no. 303027EN
• Rosemount TankRadar REX Technical Description,
Ref. no. 703010EN.

3
Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
Chapter 3 Scope of the Product
3. Scope of the Product
3.1 Purpose of the Product
The Rosemount TankRadar Rex 3900 Series is designed for high
performance level gauging in various types of storage tanks.
Temperature sensors, remote display unit, water level sensors,
pressure sensors, and other devices can be connected. Two
relays are available for alarm indication and overfill and dry run
protection.
3.2 Assumptions and Restrictions
Install the TankRadar Rex according to the instructions in this
document. The Rosemount TankRadar Rex Installation Manual
and the Rosemount TankRadar Rex Special Safety Instruction
provide further instructions for a safe installation.
Note that the TankRadar Rex is not safety-rated during
maintenance work, configuration changes, or other activity that
affects the Safety Function. Alternative means should be used to
ensure process safety during such activities.
False echoes within the radar beam from flat obstructions with a
sharp edge may lead to a situation where the TankRadar Rex can
no longer be used for safety related functions with the listed failure
rates, Safe Failure Fraction and PFDAVG. However, reduced proof
test intervals can help to detect such unwanted causes.
Operating conditions are available in the TankRadar Rex
Technical Description, ref no. 703010EN.
3.3 Functional Specification of the Safety Functions
The Safety Function is based on the relay output (one or two
relays) used as the primary safety variable for overfill and dry run
protection. The relay function is configured to activate the alarm
mode at a preset product Level or product Ullage (Ullage is the
space between the top of the tank and the product surface).

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Safety Manual
308020EN, Edition 1
June 2007
Rosemount TankRadar Rex
Chapter 3 Scope of the Product
TankRadar Rex is equipped with two cable outputs for intrinsically
safe and non-intrinsically safe connections, respectively. Wires
are clearly marked with numbers and designation of wires is
shown on a printed plate at the cable outputs. The transmitter can
also be equipped with an Integrated Junction Box (JBi).
W11 is for the relays, the TRL/2 Bus, and the non-intrinsically safe
power supply.
W12 is for the intrinsically safe connection of Data Acquisition Unit
(DAU), Remote Display Unit RDU40, analog inputs, and
temperature sensors.
Figure 1. Electrical connections on the TankRadar REX.
Connect to the relay ports on the W11 side, or to the X11 terminal
if the TankRadar REX with Integrated Junction Box JBi is used:
W12 Intrinsically
safe connections W11 Non-Intrinsically
safe connections
Integrated Junction Box (JBi)