Tracer Optimus T221 User manual

Author: Paul Storey
Date: 10 December 2019
Document no.: MD1064- F
Operation Manual
T221 Optimus

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Table of Contents
1Introduction .................................................................................................4
1.1 Referenced Documents .............................................................................. 4
2Safety Information .......................................................................................5
2.1 Conditions of Use ...................................................................................... 5
2.2 Radiation Protection .................................................................................. 5
2.3 Hazardous Area ........................................................................................ 5
2.4 Manual Handling ....................................................................................... 5
3System Description.......................................................................................6
3.1 Principle of Operation ................................................................................ 6
3.2 System Overview ...................................................................................... 7
3.3 System Components Description................................................................. 7
3.3.1 Source Container ................................................................................... 7
3.3.2 PRI150 Radiation Detector ...................................................................... 8
3.3.3 Optimus™ Control Module ....................................................................... 9
3.4 Measurement Arrangements..................................................................... 10
4Installation .................................................................................................11
4.1 Mechanical Installation ............................................................................ 11
4.1.1 Source Container(s) ............................................................................. 11
4.1.2 PRI150 Radiation Detector(s) ................................................................ 11
4.1.3 Optimus™ Control Module ..................................................................... 12
4.2 Electrical Installation / Wiring ................................................................... 12
4.2.1 Source Container(s) ............................................................................. 12
4.2.2 PRI150 Radiation Detector(s) ................................................................ 12
4.2.3 Optimus™ Control Module ..................................................................... 14
4.3 Software Installation ............................................................................... 17
5Commissioning and Calibration ..................................................................18
5.1 Pre-Commissioning Checks ...................................................................... 18
5.2 Calibration ............................................................................................. 18
6Operation ...................................................................................................19
6.1 Passive 4-20mA Current Loop................................................................... 19
6.2HART 7 .................................................................................................. 19
6.2.1 Device Variables .................................................................................. 19
6.2.2 Dynamic Variables ............................................................................... 21

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6.2.3 Status Information ............................................................................... 21
6.2.4 Device Specific HART 7 Commands ........................................................ 25
7Servicing and Maintenance .........................................................................28
7.1 Source Container .................................................................................... 28
7.2 PRI150 Radiation Detector(s) ................................................................... 28
7.3 Optimus™ Control Module ........................................................................ 28
8Appendix A –PRI150 Technical Data ..........................................................29
9Appendix B –Optimus™ Control Module Technical Data .............................30
Revision History ...............................................................................................31

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1Introduction
Optimus™ is an extremely reliable transmitter for the use in non-contact level
measurements. With proprietary algorithms, Optimus™ can provide accurate liquid level
readings in the presence of build-up. Additional system diagnostics are also available
including build up indication via the HART 7 interface
1
.
1.1 Referenced Documents
•Tracerco Document DD23870 –T221 System Diagram
•Tracerco Document MD1065 –T221 Quick Start Calibration
•Tracerco Document MD1014 –PRI150-A-4 Essential Safety Information
•Tracerco Document CPI0039 –PRI150 EU Declaration of Conformity
•Tracerco Document CPD1013 –T221 EU Declaration of Conformity
•Tracerco Document TD1071 –T221 HART Field Device Specification
1
The T221 Optimus Control Module is not registered with FieldComm Group, EDD is available from
Tracerco on request

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2Safety Information
2.1 Conditions of Use
The Optimus™ system must only be installed, commissioned, serviced and repaired by
trained personnel. Please contact Tracerco for further information.
2.2 Radiation Protection
The Optimus™ system is used in conjunction with one or more radioactive sources. The
typical radioactive isotope will be 137Cs however other isotopes may be used depending on
your system requirements.
The radioactive sources, their containers and shielding may only be installed, handled or
tested by appropriately trained and specifically licensed personnel. Regulations vary by
country and region. Tracerco Specialist Measurement Field Engineers are fully trained and
licensed to install, handle and test nuclear systems and are available to advise on
radiological safety. Contact Tracerco for further information.
2.3 Hazardous Area
The Optimus™ system is certified for use in certain hazardous areas. Reference should be
made to Appendix A –PRI150 Technical Data of this manual for specific details. It is
important to note the maximum range of ambient temperature in which the Optimus™
system can safely operate.
The Optimus™ detectors should never be opened whilst powered in a hazardous area.
Certified intrinsically safe wiring and isolation barriers must be used when the Optimus™
system is installed in a hazardous area. The system should be wired according to the
provided wiring details.
Repairs and maintenance of the Optimus™ system may only be carried out by trained
personnel. Contact Tracerco for further information.
The Essential Safety Information relating to the installation of this product in a hazardous
area is available in Tracerco Document MD1014 and must be consulted for safe operation.
2.4 Manual Handling
The Optimus™ system comprises of one or more source containers that can weigh in
excess of 100kg. Appropriate manual handling procedures must be in place for installation
or repair of the source containers.

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3System Description
3.1 Principle of Operation
The Optimus™ system provides a non-contact accurate liquid level measurement in
vessels in the presence of build-up on the vessel walls. Figure 1 shows two examples of
measurement systems.
Figure 1. Example configurations.
Each radiation source in the system emits a collimated beam of radiation through the
process to the PRI150 radiation detector(s). The amount of radiation that is incident on
each individual Geiger Müller tube (GM tube) within the detector(s) is inversely related to
the amount of process (including the level and build up) that is present in the radiation
path.
Each GM tube signal from within the detector(s) is transmitted via an isolated HART 4-
20mA repeater power supply to the Optimus™ control unit where proprietary algorithms
and processing are performed. The Optimus™ control unit provides system level as a
passive 4-20mA current loop signal or via the HART 7 interface where additional diagnostic
information including an indication of vessel build up is also available.

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3.2 System Overview
The Optimus™ system comprises the following main elements (depicted in Figure 2):
•Radiation source(s) and associated container(s)
•Tracerco PRI150 radiation detector(s)
•HART 4-20mA repeater power supply(s) (For example MTL5541)
•Tracerco T221 Optimus™ control module
•HART Modem and PC with Tracerco ToolBox software (for diagnostics and logging)
Figure 2. System overview.
Together, these components provide an accurate level measurement system that is
independent of the build-up on the vessel walls. The level is available as a 4-20mA signal
or via the HART 7 interface where additional diagnostic information is also available.
3.3 System Components Description
3.3.1 Source Container
One or multiple source containers are mounted on the side of the vessel so that radiation
is beamed through the process.
The source container is a metal housing that contains a small radiation emitting capsule.
It is designed to produce a collimated beam of radiation from the front of the container

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whilst providing shielding in all other directions. This collimated beam of radiation passes
through the process and onto the PRI150 radiation detector(s).
The source container has a mechanical shutter mechanism. When this mechanism is in the
closed position (shutter closed) it shields the radiation from passing through the process
and onto the PRI150 radiation detector(s). When this mechanism is in the open position
(shutter open –normal operation) the collimated beam of radiation is emitted through the
process onto the PRI150 radiation detector(s).
Figure 3. 600 Series Source Container
Note: If the system is being used for control in a live system then the shutter mechanism
should not be closed otherwise the level reported by the system will be incorrect.
3.3.2 PRI150 Radiation Detector
One or multiple PRI150 radiation detectors are mounted along the length of the vessel
opposite the source container(s) so that the collimated radiation beam passes through the
process onto them.
Inside the metal detector housing is an array of Geiger Müller tubes (GM tubes) that
produce a discharge when radiation is incident on them. These discharges (known as
counts) are observed by the detector electronics and microprocessor which convert these
counts into packets of data that can be read from the detectors.

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Figure 4. Tracerco PRI150 radiation detectors.
The PRI150 radiation detector is suitable for use in certain hazardous areas. Reference
should be made to Appendix A –PRI150 Technical Data of this manual for specific details.
The Essential Safety Information can be found in Tracerco Document MD1014.
3.3.3 Optimus™ Control Module
The Optimus™ control module is not suitable for use in hazardous areas and is normally
situated in the control cabinet in the safe area. It can be mounted using top hat 35mm
DIN rail.
Each PRI150 radiation detector in the system connects to the Optimus™ control module
via an isolated HART 4-20mA repeater power supply. Proprietary algorithms and
processing are performed on the system data to provide the system level as a passive 4-
20mA loop current signal or via the HART 7 interface where additional diagnostic
information including an indication of vessel build up is also available.
Figure 5. Optimus™ control module.

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3.4 Measurement Arrangements
Optimus™ is an externally mounted system and therefore is not affected by adverse
conditions in the vessel (high pressures, temperatures, corrosive liquids). The system can
be used on numerous different shaped vessels.
Up to four PRI150 radiation detectors can be connected to a single Optimus™ control
module. This allows a measurement range between 0.24 to 17.28 metres in 0.24 metre
increments.

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4Installation
4.1 Mechanical Installation
Tracerco Specialist Measurement Project Engineers will work with you to capture your
system requirements. This will include producing a system general arrangement drawing
that will detail the mounting positions of the source container(s) and PRI150 radiation
detectors. Tracerco Project Engineers will also advise on bracket design for mounting the
equipment to the vessel.
Any frameworks and/or structures, both external and internal to the vessel (for example,
stiffening rings, platform supports, agitator, and so on), should be identified and the
details passed on to the Tracerco Project Engineer. The system will have to be designed
to avoid these structures in order to obtain optimum performance and allow delivery of
the correct source size to achieve this performance.
4.1.1 Source Container(s)
The source container is mounted on brackets, typically attached directly to the vessel.
Attention should be made to the following:
•Mounting brackets must be fabricated exactly as shown on the bracket drawings
supplied by Tracerco. Errors in fabrication could lead to significant degradation in
system performance.
•Brackets must be constructed so that the gap between the front face of the source
container and the vessel is fully enclosed. This is to provide the necessary
protection from scattered radiation and also to prevent finger access to the source
beam.
•The front mounting plate must incorporate a hole as advised by Tracerco to avoid
unnecessary attenuation of the radiation beam.
•There must be a clearance of at least 250mm (10”) on the side of the container
that holds the arming rod mechanism. This is to allow the arming rod mechanism
to be opened and closed. If this is not possible, then Tracerco must be contacted
to advise on repositioning whilst maintaining optimum performance.
WARNING! Source containers contain extremely dense materials and therefore are heavy.
Suitable lifting precautions must be taken when mounting.
4.1.2 PRI150 Radiation Detector(s)
The PRI150 radiation detectors are mounted on brackets, typically attached directly to the
vessel. Attention should be made to the following:
•There are labels placed at the end of the detectors (MOUNT BRACKET
ABOVE/BELOW THIS LINE) showing the limits of the sensitive region. Where ever
possible, mounting brackets should be placed outside of the sensitive region.
•Mounting brackets must be fabricated exactly as shown on the bracket drawings
supplied by Tracerco. Errors in fabrication could lead to significant degradation in
system performance.

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•Care should be taken to avoid excessive shock when mounting the equipment.
•The sensitive length shown on the detector should be positioned in the correct
measurement range on the outside of the vessel as shown on the general
arrangement drawings. If this is not possible, then Tracerco must be contacted to
advise on repositioning whilst maintaining optimum performance.
4.1.3 Optimus™ Control Module
The Optimus™ control module is designed for use in the safe area. It is mounted on Top
Hat 35mm DIN rail in the control cabinet. It is normally mounted beside the HART 4-20mA
repeater power supplies required by the PRI150 radiation detectors.
4.2 Electrical Installation / Wiring
Reference should be made to Tracerco Document DD23870 –T221 System Diagram.
4.2.1 Source Container(s)
There are no electrical connections to be made to the source container(s).
4.2.2 PRI150 Radiation Detector(s)
The PRI150 radiation detector is approved for use in certain hazardous areas. Details on
regarding hazardous area certification can be found in Appendix A –PRI150 Technical
Data.
Particular attention should be given to the essential safety information. This can be found
in Tracerco Document CPI0039.
Figure 6. PRI150 terminals.

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The PRI150 requires two wires from the field. Figure 7 shows an extract from Tracerco
Document DD23870 detailing the PRI150 wiring. Attention is drawn to the requirement for
an internal connection between terminals 1 and 3 on the PRI150. Without this connection
the device will fail to communicate with the Optimus™ control module.
Figure 7. PRI150 connections.
A HART 4-20mA repeater power supply is required to provide both power and isolation to
the PRI150 radiation detector. Tracerco recommends the use of the MTL 5541 module to
provide this functionality. A HART 4-20mA repeater power supply is required for each
PRI150 radiation detector in the system. There is a safe area connection to the Optimus™
control module. Table 1 details the connections of the MTL 5541 barrier.
Terminal
Description
1
I OUT (Connect to Pin 1 of PRI150)
2
+ VE (Connect to Pin 2 of PRI150)
3
-VE (Not used)
10
Current Output +VE via 220Ω resistor (Not used during normal operation)
11
Current Output –VE (To T221)
12
Current Output +VE (To T221)
13
Power Input –VE
14
Power Input +VE (24Vdc)
Table 1. MTL5541 connections.

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4.2.2.1 Earthing
The PRI150 radiation detector case must be earthed to a local earthing point near the
vessel. An earthing cable is supplied pre-attached to the PRI150 radiation detector case
(Figure 8).
Figure 8. Earthing connection on PRI150.
4.2.3 Optimus™ Control Module
Figure 9 shows an extract from Tracerco Document DD23870 detailing the T221 Optimus™
wiring. The Optimus™ control module requires a nominal 24VDC supply (connected to pins
7 and 8) and consumes < 2W. The input voltage range is 20 to 35VDC.
Figure 9. Optimus™ connections.
4.2.3.1 Optimus™ Input Channels (PRI150 HART 5 Inputs)
The Optimus™ control module can be connected to between one and four PRI150 radiation
detectors. The connection between the Optimus™ control module and the PRI150 radiation
detector must be made via a suitable HART 4-20mA repeater power supply such as the
MTL 5541 (see section 4.2.2 for details of the MTL 5541 connections). Optimus™ must
NOT be connected directly to field mounted PRI150 radiation detectors.

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The Optimus™ control module inputs provide the required 250Ω impedance required for
HART communications. Optimus™ has been designed to handle up to 80mA combined
input current.
All of the input channel terminals are connected in parallel in the Optimus™ control
module. The location of a PRI150 radiation detector within the system is determined by
the configuration settings stored in the Optimus™ control module. The configuration maps
the unique HART address of each PRI150 radiation detector to the assigned channel. The
terminal numbering is provided for convenience in case the need for troubleshooting
arises.
4.2.3.2 Optimus™ HART 7 4-20mA Output
Optimus™ presents the level output as a passive 4-20mA current loop with HART 7
communications available over the current loop. The 4-20mA current output must be
connected to an active input on the plant DCS (for example, the DCS powers the current
loop).
In order to utilise HART 7 communications the appropriate impedance (250Ω) must be
present in the loop.
Additional terminals are made available on the front of the Optimus™ control module to
connect a HART modem (orange connector). This is to allow communications with the
Optimus™ control module for calibrating and monitoring purposes. This signal is digital
only and does not provide a 4-20mA signal. For these terminals to operate correctly, the
4-20mA output should be correctly powered with the correct impedance (250Ω).
Figure 10. Local display.

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4.2.3.3 Local Display
There are six LEDs on the front of the Optimus™ control unit. This is shown in Figure 10.
These indicators make up a multifunction display that reflects the current power,
communication and status of the control module. Each LED has the capable of being RED,
YELLOW or GREEN. Table 2 describes the purpose of each LED:
LED
Description
PWR
Power and Device Status
CH1
PRI150 Channel 1 Status and Communications
CH2
PRI150 Channel 2 Status and Communications
CH3
PRI150 Channel 3 Status and Communications
CH4
PRI150 Channel 4 Status and Communications
HART
Host Communications Status
Table 2. Local display overview.
Normal Operation
LED
State
Description
PWR
Green
Device Powered and Operating
Yellow
Device Powered and Operating with a Warning
Red
Device Powered and in Error
CH1-4
Green
Channel Enabled and Operating
Yellow
Channel Enabled and Operating with Warning
Red
Channel Enabled and in Error
Flickering
T221 Communicating with Channel
Off
Channel Not Enabled
HART
Green
T221 Communicating with Host
Yellow
Host Communicating with Optimus™
Off
No Ongoing Communications with Host
Table 3. Local display during normal operation.
Start Up Sequence
On device power-up (or after a device reset), the LEDs will perform the following test
sequence to demonstrate proper operation:
1. Flash all LEDs RED
2. Flash all LEDs YELLOW
3. Flash all LEDs GREEN
Squawk

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The HART “squawk” feature has been implemented in the Optimus™ control module. A
single squawk sequence will be the same as the test sequence performed on power up.
Continuous squawking will be the same sequence repeated.
PRI150 Discovery Mode
To indicate that the T221 control module is in PRI150 Discovery Mode, LED 1 (power and
status) will alternate between RED and YELLOW at 1Hz (i.e. 500ms RED, 500ms YELLOW).
LED
State
Description
PWR
Red/Yellow
In PRI150 Discovery Mode
CH1-4
1Hz Green
Channel Currently Being Discovered
Green
Channel Discovered
Yellow
Channel Yet to be Discovered
Off
Channel Not to be Discovered
HART
Green
T221 Communicating with Host
Yellow
Host Communicating with T221
Off
No Ongoing Communications with Host
Table 4. Local display during PRI150 Discovery Mode.
After the last PRI150 channel has been discovered, the device will stay in PRI150 discovery
mode for a further 1 second. This is to allow the end user to see that the channel has
successfully been discovered.
4.3 Software Installation
To fully utilise the Optimus™ calibration and advanced diagnostics, the Tracerco ToolBox
software must be installed. Refer to the Tracerco ToolBox documentation.
Currently, there is no HART device descriptor available. However, the necessary HART
details are provided to implement advance functionality in your DCS. Refer to Tracerco
Document TD1071 T221 HART Field Device Specification for complete details.

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5Commissioning and Calibration
5.1 Pre-Commissioning Checks
The commissioning engineer should ensure that the mounted system (source container(s),
PRI150 radiation detector(s)) are all mounted as per the general arrangement drawing for
the system.
Additional attention should be drawn to check for any obstructions, both internally and
externally, in the path between the radiation source and detectors that has not already
been noted on the general arrangement drawing. Any obstruction will reduce the
performance of the system, especially around the region of the obstruction. If obstructions
are identified then Tracerco should be contacted in order to provide advice and
recommendations to achieve an optimum system.
5.2 Calibration
Optimus™ utilises specially developed algorithms to perform its level calculation and
provide additional diagnostics such as build up indication. The Tracerco ToolBox software
provides the necessary tools to perform a complete calibration.
Figure 11. Tracerco ToolBox.
Please refer to Tracerco Document MD1065 –T221 Quick Start Calibration for a complete
guide through the calibration procedure.

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6Operation
6.1 Passive 4-20mA Current Loop
The passive 4-20mA current loop always represents the system level independent of build-
up on the vessel walls. This is the same value that is presented as the primary variable on
the HART 7 interface.
The passive 4-20mA current loop output is required to be connected to an active 4-20mA
input that provides power for the current loop.
6.2 HART 7
HART 7 communication is available over the 4-20mA loop. To communicate with the
Optimus™ control module you require either a HART 7 active DCS or a HART modem and
PC with the Tracerco ToolBox software.
The following sections provide the basic HART information required to obtain status
information from the device. For a complete description of the HART implementation
please refer to Tracerco document TD1071 T221 HART Field Device Specification.
6.2.1 Device Variables
The Optimus™ controls module supports 151 Device Variables. The table below provides
a summary.
Note: Channels are numbered from the bottom up. Also, GM tube counters within each
channel are numbered from the bottom up.
Number
Name
Classification
Unit Codes
0
Process Level
Analytical (81)
Percent (57)
1
Maximum Build Up
Length (69)
cm (48)
2
Elevation of Maximum Build Up
Analytical (81)
Percent (57)
3
Average Gas Phase Build Up
Length (69)
cm (48)
4
Average Total Build Up
Length (69)
cm (48)
5
Process Level by Traditional
Calculation
Analytical (81)
Percent (57)
6
Radiation Source Strength
Analytical (81)
Percent (57)
7-78
Normalised Stage Count Rates (Up
to 72)
Not Classified (0)
None (251)
79-150
Build Up per Stage (Up to 72)
Length (69)
cm (48)
Table 5. Device variables.
6.2.1.1 Device Variable 0 –Process Level
This Device Variable has a fixed mapping to the Primary Variable. It represents the process
level and is resistant to:

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•Solids build up on the vessel wall
•Variations in pressure.
6.2.1.2 Device Variable 1 –Maximum Build Up
Optimus™ is capable of providing an up to date indication of solids build up on the vessel
wall for stages that are in the gas phase. This Device Variable reports the value of the
stage with the maximum build up present.
6.2.1.3 Device Variable 2 –Elevation of Maximum Build Up
Optimus™ is capable of providing an up to date indication of solids build up on the vessel
wall for stages that are in the gas phase. This Device Variable reports the elevation of the
centre of the stage with the maximum build up present.
6.2.1.4 Device Variable 3 –Average Gas Phase Build Up
Optimus™ is capable of providing an up to date indication of solids build up on the vessel
wall for stages that are in the gas phase. This Device Variable reports the average build-
up of all stages currently in the gas phase.
6.2.1.5 Device Variable 4 –Average Total Build Up
Optimus™ is capable of providing an up to date indication of solids build up on the vessel
wall for stages that are in the gas phase. This Device Variable reports the average build-
up of all stages.
6.2.1.6 Device Variable 5 –Process Level by Traditional Calculation
This Device Variable provides the process level as it would have been reported using
traditional nucleonic calculation. This level is NOT resistant to:
•Solids build up on the vessel wall
•Variations in pressure
6.2.1.7 Device Variable 6 –Radiation Source Strength
Radiation sources decay with time. The amount of decay is related to the radio nuclide.
This Device Variable reports the source strength as a percentage of its strength at the
calibration date.
6.2.1.8 Device Variables 7-78 –Normalised Stage Count Rates
Optimus™ supports up to 72 stages. Each stage has a count rate between 0 and 1 which
represents the amount of radiation incident on that stage. These normalised count rates
are represented by these Device Variables.
Device Variable 7 represents Stage 1, Device Variable 8 represents Stage 2 and so on.
If a particular stage does not exist for the current device configuration then a value of 0
is returned.