Varec RS-232 User manual

IOM095GVAE4112
Automation Solutions for oil & gas, defense and aviation applications
Installation and Operations Manual
Dispatch and Fuels Accounting
8410 Wireless Field
Transceiver
Transmitter and receiver for wireless
RS-232 and RS-485 data
communications

Varec, Inc. iii
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), Georgia 30092
Phone: [phone]
Fax: [phone]
Trademarks Acknowledged
Varec, Inc. recognizes all other trademarks. Trademarks of other products mentioned in this
manual are held by the companies producing them.
FuelsManager®, TankView®, TacFuels®, Varec®, and FuelsManager IntoPlane® are registered
trademarks of Varec, Inc.
FreeWave® is a registered trademark of FreeWave Technologies, Inc.
All other product and service names mentioned are the trademarks of their respective
companies.

Disclaimer of Warranties
The contract between the Seller and the Buyer states the entire obligation of the Seller. The
contents of this instruction manual 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 instruction manual. The only warranties that apply are those
in the existing contract between the Seller and Buyer.
The 8410 Wireless Field Transceiver (WFT) has not been tested by Varec under all possible
operational conditions, and Varec may not have all the data relative to your application. The
information in this instruction manual 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 or her application. If you have any further questions, please contact Varec for
assistance.
Limitations of Seller's Liability
In the event that a court holds that this instruction manual 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.
Use of parts that are not manufactured or supplied by Varec voids any warranty and relieves
Varec of any obligation to service the product under warranty. Varec recommends the use of
only Varec manufactured or supplied parts to maintain or service Varec 8410 Wireless Field
Transceivers.
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.
This manual is solely intended to describe product installation and functions and should not be
used for any other purpose. It is subject to change without prior notice. This manual was
prepared with the highest degree of care. However, should you find any errors or have any
questions, contact one of our service offices or your local sales agent.
iv Installation and Operations Manual

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 this manual carefully and make sure you understand its contents before using this product.
Follow all instructions and safety guidelines presented in this manual when using this product.
If the user does not follow these instructions properly, Varec cannot guarantee the safety of the
system.
Note Comply with all applicable regulations, codes, and standards. For safety precautions,
the user should refer to the appropriate industry or military standards.
Caution! Electrical Hazard! Read and understand static and lightning electrical protection
and grounding described in API 2003. Make certain that the tank installation, operation,
and maintenance conforms with the practice set forth therein.
Varec, Inc. v

Restricted Rights
This product is licensed by The United States. Diversion contrary to U.S. law is prohibited.
Shipment or re-export of this product outside of The United States may require authorization
by the U.S. Bureau of Export Administration. Please contact Varec, Inc. for assistance and further
information.
FCC Notifications
This device complies with part 15 of the FCC rules. Operation is subject to the following two
conditions: 1) This device may not cause harmful interference and 2) this device must accept
any interference received, including interference that may cause undesired operation. This
device must be operated as supplied by Varec, Inc. Any changes or modifications made to the
device without the express written approval of Varec, Inc. may void the user’s authority to
operate the device.
This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This equipment generates, uses, and
can radiate radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by turning
the equipment off and on, the user is encouraged to try to correct the interference by one or
more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
• Consult the dealer or an experienced radio/TV technician for help.
vi Installation and Operations Manual

Wireless Field Transceiver
Varec, Inc. vii
Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Function and System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Internal system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Understanding Data Communication Configurations . . . . . . . . . . . . . . . . . . . . . 4
1.3.1 Point-to-Point systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.2 Point-to-Multipoint systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Choosing Point-to-Point or Point-to-Multipoint Operation. . . . . . . . . . . . . . . . . . 6
2 Preparing for Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Pre-Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 General Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.1 Identifying your sites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.2 Completing a site study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.3 Selecting an antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5.4 Configuring radios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.5 Installing cables and antennas properly . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.6 Surge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Installation Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 8410 WFT Connectors, Switches, and Wiring Diagram (AC Version) . . . . . . . 16
4.1.1 Connector assignments for the AC version. . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 8410 WFT Connectors, Switches, and Low Voltage Wiring Diagram
(DC Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.1 Connector assignments for the low voltage version . . . . . . . . . . . . . . . . . . . 19
5 Setting Up the Transceiver Using Tool Suite . . . . . . . . . . . . . . . . . . . 21
5.1 Setting Up a Transceiver Using Tool Suite. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 LED Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 LED Operations on a Point-to-Multipoint System . . . . . . . . . . . . . . . . . . . . . . . 23
6.1.1 Point-to-Multipoint operation LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 LED Operations on a Point-to-Point System. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.1 Point-to-Point operation LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Contents
viii Installation and Operations Manual
7 Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.2 Transmit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.3 Receive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.4 Data Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8.5 Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.6 Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9 Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 Order Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Wireless Field Transceiver
Varec, Inc. 1
1 Introduction
This manual provides the information that the user needs to install, maintain, and troubleshoot
the Varec 8410 Wireless Field Transceiver (8410 WFT).
1.1 Overview
The 8410 WFT provides secure wireless communications between the field instrument and the
8420 Wireless Base Transceiver (WBT), which is located in the control room. Both units are able
to provide simultaneous slave/repeater functionality.
The 8410 WFT and the 8420 WBT provide wireless links between a variety of instruments and
devices. The units can be configured to provide wireless communications with most RS-232 and
RS-485 serial devices including the Varec 4590 TSM, Varec 2900 FTT, and Varec 8130 RTU.

Introduction
2Installation and Operations Manual
1.2 Function and System Design
The 8410 WFT provides wireless 900 MHz RS-232 and RS-485 data communications.
Figure 1-1: Example of Point-to-Point and Multipoint Systems
Varec’s wireless products are able to function over point-to-point or multipoint systems.
Traditionally, a multipoint network is used in applications where data is collected from many
instruments and reported back to one central site.
Note It is important to note the differences between point-to-point and point-to-multi-
point systems. In a point-to-point system all data communications are acknowledged,
whether sent from the master to the slave or from the slave to the master. In a point-to-
multipoint system outbound communications from the master are sent a user-defined
number of times. The receiving unit, slave or repeater, will accept the first packet received
that meets security requirements. A point-to-point system is limited to one master and one
slave transceiver. Repeaters may be added to extend the reach of the network, but no other
master or slave may be added. In a point-to-multipoint system, the transceiver—desig-
nated as a master— is able to communicate with numerous slaves. In its simplest form, a
tank gauge multipoint network functions with the master (8420 WBT) broadcasting its mes-
sages to all slaves (8410 WFT) and the slaves responding to the master when given data by
the connected tank gauge transmitter.
FuelsManager
Software
8130 RTU
or
8300 TGI
Loop Communcations e.g. Modbus
Star Communcations e.g. Mark/Space
Field
Junction Box
+24V
+5V
+15V
-15V
CPU
COMM
I/O
ERROR
Point-to-Point
Master
WBT
Point-to-MultiPoint
Slave
Slave
Slave
CDTXCTS
Model8420WirelessBase Tr ansceiver
16-xxxxxx-1 MadeinUSA
Varec,Inc.
5834PeachtreeCornersEastNorcross(Atlanta) Georgia30092USA
8420
CDTXCTS
Model8420Wireless Base Transceiver
16-xxxxxx-1MadeinUSA
Varec,Inc.
5834PeachtreeCornersEastNorcross (Atlanta) Georgia 30092 USA
8420
CDTXCTS
Model8420WirelessBaseTransceiver
16-xxxxxx-1MadeinUSA
Varec,Inc.
5834PeachtreeCornersEastNorcross(Atlanta)Georgia30092USA
8420
\Repeater

Wireless Field Transceiver
Varec, Inc. 3
1.2.1 Internal system design
A. Antenna
B. Antenna Feed-Thru
C. Electronics Assembly
D. O-Ring
E. Housing
All standard electronics for the 8410 WFT are contained on the circuit board (C). This includes
power, field communications, a 3-wire temperature input, and a 24V DC out.
Figure 1-2: 8410 WFT System Components
D
B
C
A
E

Introduction
4Installation and Operations Manual
1.3 Understanding Data Communication Configurations
The 8410 WFT’s versatility allows the user to establish data communication links using a variety
of configurations. This makes it possible to extend the range of the 8410 WFT and operate in a
number of applications. This section describes the two main categories of communication
configurations: Point-to-Point and Point-to-Multipoint.
1.3.1 Point-to-Point systems
A point-to-point system is limited to one master and one slave transceiver. Repeaters may be
added in to extend the reach of the network, but no other master or slave may be added.
The example below shows the most common and straightforward link, a master communicating
to a slave in a point-to-point link.
Figure 1-3: A Master Communicating to a Slave in a Point-to-Point Link
The following diagram shows how a link might be set up using a repeater. The repeater may be
sitting on a hilltop or other elevated structure to link the master to the slave. In this setup, it
may be desirable to use an external omni-directional antenna on the repeater. To extend the
range, Yagi antennas may be used on either or both of the master and slave transceiver.
When a repeater is used, the network capacity is cut in half.
Figure 1-4: A Link Setup Using a Repeater
The example below shows a link with two repeaters between the master and slave. With two
repeaters there is clearly more flexibility in getting around obstacles and a greater total range
is possible. Once again, it would be desirable to use external omni-directional antennas with
the repeaters, and attaching a Yagi to the master and slave to increase the range of the link.
When two repeaters are used there is no further degradation in the network capacity of the link.
Figure 1-5: A Link with Two Repeaters Between the Master and Slave
8420 WBT 8410 WFT
8420 WBT 8410 WFT 8410 WF
T
8420 WBT 8410 WFT
8410 WFT
8410 WFT

Wireless Field Transceiver
Varec, Inc. 5
1.3.2 Point-to-Multipoint systems
In a point-to-multipoint system the transceiver, designated as a master, is able to communicate
with numerous slaves. In its simplest form, a multipoint network functions with the master
broadcasting its messages to all slaves and the slaves responding to the master when given data
by the device connected to the data port.
Figure 1-6 depicts a standard point-to-multipoint system. In this example, any data sent from
the master is broadcasted to all three slaves, one of which receives it through a multipoint
repeater. The data is in turn sent out of the RS-232 or RS-485 port of each of the three slaves.
Figure 1-6: A Standard Point-to-Multipoint System Using a Multipoint Repeater
Figure 1-7 shows a point-to-multipoint system using a slave/repeater at one of the sites. This
system works in the same manner as a standard multipoint system with repeaters. However, the
number of radios needed is reduced with the use of the multipoint slave/repeater feature.
Figure 1-7: A Point-to-Multipoint System Using the Multipoint Slave/Repeater Feature
8410
WFT
8410
8420 8410
WFT
WBT
8410
8410
8410
8410
8410

Introduction
6Installation and Operations Manual
1.4 Choosing Point-to-Point or Point-to-Multipoint Operation
It is important to note the differences between point-to-point and point-to-multipoint systems.
In a point-to-point system all packets are acknowledged, whether sent from the master to the
slave or from the slave to the master. In a point-to-multipoint system, outbound packets from
the master or repeater to slaves or other repeaters are sent a user-defined number of times. The
receiving transceiver, slave or repeater, will accept the first packet received that passes the 32-
bit CRC. However, the packet is not acknowledged. On the return trip to the master, all packets
sent are acknowledged or retransmitted until they are acknowledged.
Traditionally, a multipoint network is used in applications where data is collected from many
instruments and reported back to one central site. As such, the architecture of such a system is
different from point-to-point applications. The number of radios in a point-to-multipoint
system is influenced by the following parameters:
1. Size of the blocks of data. The longer the data blocks, the smaller the system capacity.
2. Baud rate.
3. The amount of contention between slaves. Polled slaves verses timed slaves.
4. Use of repeaters. Using the repeater setting in a multipoint network will decrease overall
system capacity by 50%.
For example, if the network will be polling slaves once a day to retrieve sparse data, several
hundred slaves could be configured to a single master. However, if each slave will be
transmitting data more frequently, the system will be closer to capacity and fewer slaves should
be linked to the master.
For examples and additional information on data communication links, please consult
Varec, Inc.

Wireless Field Transceiver
Varec, Inc. 7
2 Preparing for Installation
This chapter provides a pre-installation checklist, safety information, unpacking instructions,
and an overview of the installation steps for the 8410 WFT.
2.1 Pre-Installation Checklist
Before you install the 8410 WFT in the field be sure:
1. The field device is operating correctly.
2. There is sufficient space to install the transmitter and accessories, such as conduit and
cabling. Refer to Figure 2-1 for housing dimensions.
Figure 2-1: 8410 Wireless Field Transceiver Dimensions
3. To have the correct field connections at the field device ready to connect to the 8410 WFT,
such as power and communications.
4. To be in compliance with the safety guidelines described in Section 2.2, "General Safety
Guidelines" on page 8.
3/4” NPT
3/4” NPT
3/4” NPT
Ground
Connector
Ground
Connector
5 15/16 “
(151)
O. A.
4 13/16”
(122)
DIA.
(2) 1/4” (6) DIA. MOUNTING HOLES
4 3/4”
(121) 5 1/2”
(140)
MOUNTING
6 1/8”
(156)
O.A.
2 3/16”
(56)
5 15/64 “ (133)
O. A. (REF.)
3 1/2” (89)
O. A. (REF.)
3 3/16”
(81)
1 15/16”
(49)
1 3/4”
(44)
1 1/16”
(27)
(2) 3/4” - 14 NPT
CONDUIT HUBS

Preparing for Installation
8Installation and Operations Manual
2.2 General Safety Guidelines
The user should follow safety guidelines provided by the Occupational Safety and Health
Administration (OSHA) for additional protection. Information may also be obtained from the
following sources:
• National Electric Code (NEC)
• National Fire Protection Association (NFPA)
• Instrument Society of America (ISA)
• Factual Mutual Research Corporation (FM)
• Underwriters Laboratories Incorporated (UL)
When in doubt about the safety of an area, the user should check with the local safety
authorities. Always observe equipment labels and warning signs posted in the area.
2.3 Unpacking
Varec 8410 Wireless Field Transceivers are shipped fully assembled and ready for installation.
To unpack the 8410 WFT:
1. Place the shipping container on a secure bench.
2. Open the shipping container, taking care not to damage the contents.
3. Carefully remove the transceiver from the shipping container and place it on the bench.
4. Inspect the transceiver for shipping damage. Report any damage to the carrier.
Note If the transceiver must be stored prior to installation, it should be repacked in its
shipping container and stored in a temperature-and humidity-controlled environment.

Wireless Field Transceiver
Varec, Inc. 9
2.4 Installation Overview
To install the transceiver, follow the pre-site preparation steps shown in the following flowchart:
Figure 2-2: 8410 WFT Installation Sequence
Site
Identification Site Study Configure Radios
Equipment
Installation
Antenna
Selection

Preparing for Installation
10 Installation and Operations Manual
2.5 Installation Checklist
By following a simple process to install the 8410 WFT, one can ensure a pain-free installation
resulting in a successful robust communications system.
The following sections will help guide you through the pre-site preparation process.
2.5.1 Identifying your sites
Identify sites with “Line of Sight”. If you cannot see it, you cannot talk to it. In general, higher is
better, however:
• Long cable runs can decrease the signal strength and are more susceptible to noise
• A higher antenna is able to broadcast over a larger area
• A higher antenna may pick up more noise and interference from other RF signals in the area
• A high antenna or cables are more susceptible to damage from lightning strikes
2.5.2 Completing a site study
To complete a site study, do the following:
• Verify that all antenna locations have line of site to the master radio or to a nearby repeater.
• Plan a sight outline with slaves/repeaters and determine how each unit will communicate
back to the master.
2.5.3 Selecting an antenna
An antenna is a device that is made to efficiently radiate and receive radiated electromagnetic
waves.
There are several important antenna characteristics that should be considered when choosing
an antenna for your application:
• Antenna radiation patterns/antenna type
• Power gain
• Directivity
• Polarization
Consult with Varec, Inc. to choose the proper antennas for each 8410 WFT and 8420 WBT
location.

Wireless Field Transceiver
Varec, Inc. 11
2.5.4 Configuring radios
To configure the radios, do the following:
• Configure all slave/repeater radios
This is most easily done on the bench; however, radios may be programmed in the field if
necessary. Refer to the
FreeWave ToolSuite Manual for more information.
• Verify that there is a proper communications link to the master.
2.5.5 Installing cables and antennas properly
To properly install cables and antennas, ensure that:
• There are no major bends in the RF cables
• All RF connections are secure and waterproof
2.5.6 Surge protection
Caution Surges caused by near or direct lightning strikes can severely damage the
equipment.
Varec recommends installing surge protection on any exterior antenna or antenna cables.

Preparing for Installation
12 Installation and Operations Manual