Varec 4532 User manual

Varec, Inc.
5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA
Tel: [phone] Fax: [phone]
www.varec.com
IOM019NVAE0208
4532 Average Temperature Sensor and
Converter
Installation and
Operations Manual
For software version V1.45

Varec, Inc. 1
4532
Copyright
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.
Varec® is a registered trademark of Varec, Inc., a wholly-owned subsidiary of
Science Applications International Corporation

Average Temperature/Water Bottom Sensor and Converter
2 Installation and Operations Manual
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.
Terms of Use
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.
Use of parts that are not manufactured or supplied by Varec, Inc. invalidates the agency
approval for this product.

Varec, Inc. 3
4532
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 the Varec 4532 Average Temperature Sensor and Converter. Follow all
precautions and warning noted herein when installing, operating or performing
maintenance on this equipment.

Average Temperature/Water Bottom Sensor and Converter
4 Installation and Operations Manual

Varec, Inc. 1
4532 Contents
Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Installation and operation overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Software history. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 System functional diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Installation, commissioning and operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Product Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.1 Power source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.2 Use in hazardous areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2.3 External connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3.1 Hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3.2 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Notes on safety conventions and symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Device designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1.1 Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 CE marks, declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Design, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Flexible tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Special conditions for safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Mounting instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Mounting on a fixed roof tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.1 Top anchor method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.2 Thermo well method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Contents Average Temperature/Water Bottom Sensor and Converter
2 Installation and Operations Manual
5.2.3 Anchor weight method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Mounting on a floating roof tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3.1 Top anchor method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3.2 Thermo well method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.3 Guide ring and anchor weight method . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Terminal Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.1 4532 ATC terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.2 6000 Series Servo Tank Gauge terminal . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.3 4590 TSM i.s. terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Local HART connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.1 As a Varec tank gauging instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.2 As a standalone generic HART instrument . . . . . . . . . . . . . . . . . . . . . . . 27
7.2 Device set up: 4590 TSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.1 HART scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.2 The 4532 ATC specific parameter set up on the 4590 TSM . . . . . . . . . . . 28
7.3 Device set up: 6000 Series Servo Tank Gauge . . . . . . . . . . . . . . . . . . . . . 28
7.3.1 Preparation of 6000 Series Servo Tank Gauge . . . . . . . . . . . . . . . . . . . . 28
7.3.2 4532 ATC configuration on 6000 Series Servo Tank Gauge . . . . . . . . . . . 28
8 Operation and Description of Instrument Function . . . . . . . 31
8.0.1 HART Device designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.0.2 Device Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Temperature measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.1 Primary values: VH00 ~ VH09. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1.2 Element Temperature 1: VH10 ~ VH15 . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.3 Element Temperature 2: VH20 ~ VH29 . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1.4 Element Position 1: VH30 ~ VH35
(VH36~VH39 is used only in 4539 ATC)35
8.1.5 Element Position 2: VH40 ~ VH45 are not available in 4532 ATC . . . . . . . 35
8.1.6 WB primary and Advanced temp: VH50 ~ VH59 . . . . . . . . . . . . . . . . . . . 37
8.1.7 WB Adjustment and Operation Power: VH60 ~ VH69 . . . . . . . . . . . . . . . 38
8.1.8 Temperature Adjustment: VH70 ~ VH79. . . . . . . . . . . . . . . . . . . . . . . . . 38
8.1.9 Device setting 2: VH90~VH99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Exterior cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.3 Repairs to Ex-approved devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.4 Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Varec, Inc. 3
4532 Contents
10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.1 System error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.1 Anchor weight (Tall profile) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.2 Anchor weight (Low profile) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.3 Wire hook, Top anchor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
12 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
A Order Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
B Declaration of Contamination Form . . . . . . . . . . . . . . . . . . . . . . . 55
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Contents Average Temperature/Water Bottom Sensor and Converter
4 Installation and Operations Manual