Varec 8200 User manual

IOM005GVAE3713
Automation Solutions for oil & gas, defense and aviation applications
Installation and Operations Manual
s
patch and Fuels Accounting
8200 Current Output
Transmitter
Signal transmission for accurate level
measurement in storage tanks

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.
All other product and service names mentioned are the trademarks of their respective
companies.
Product Approvals
This document and the information provided within are controlled by the approvals agency(s)
listed below. All changes to this document must be submitted to and approved by the agency(s)
before public release.
• FM Approvals (FM)

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 8200 Current Output Transmitter (COT) 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 8200 Current Output
Transmitters.
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.
Warning! Striking the gaugehead with a metal object could cause a spark to occur. When
removing or replacing the gaugehead in flammable or hazardous liquid storage areas, take
necessary measures to protect the gaugehead from impact.
Warning! Volatile fumes may be present! Ensure that the tank has been leak and pressure
tested as appropriate for the liquid to be stored. Observe appropriate safety precautions in
flammable or hazardous liquid storage areas. Do not enter a tank that has contained
hydrocarbons, vapors, or toxic materials, until a gas-free environment is certified. Carry
breathing equipment when entering a tank where oxygen may be displaced by carbon
dioxide, nitrogen, or other gases. Wear safety glasses as appropriate. Use a hard hat.
Warning! Sparks or static charge could cause fire or explosion! The mechanical
connections between the guide cables, the float, the tape, and the gaugehead provide a
resistance to ground that is adequate for the safe electrical drain of electrostatic charges
that may accumulate in the tank and the product. Worker activity and worker clothing may
accumulate electrostatic charges on the body of a worker. Care should be used in
flammable environments to avoid the hazard.
Warning! Broken negator motor spring pieces can cause injury when the back cover of the
gaugehead is removed! Whenever the back cover is removed, stand to one side as the last
bolt is removed.
Varec, Inc. v

vi Installation and Operations Manual

Current Output Transmitter
Varec, Inc. vii
Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Getting Acquainted with the Varec Current Output Transmitter . . . . . . . . . . . . . 1
2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Storage Prior to Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Mounting on Varec Gaugeheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Mounting on Alternate Gaugeheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Field Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.1 With AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.2 User-Furnished DC Power (Loop Powered) . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 AC Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.8 Signal and Switch Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.9 Junction Boxes and Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.10 Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.11 Loop Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.12 Installation Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Initial Checkout and Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Limit Switch Operational Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Major System Assemblies and Components . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Available Level Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6 Order Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Device Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.2 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Contents
viii Installation and Operations Manual

Current Output Transmitter
Varec, Inc. 1
1 Introduction
This manual is designed to assist the user in the installation, operation, calibration, and
maintenance of the Varec 8200 Current Output Transmitter (8200 COT).
1.1 Getting Acquainted with the Varec Current Output Transmitter
The 8200 COT is an electromechanical device that is mechanically coupled to the sprocket drive
sheave of a Varec 2500 Automatic Tank Gauge (2500 ATG) gaugehead or other liquid level
indicating gaugehead (see Figure 1-1).
Figure 1-1: Varec 8200 Current Output Transmitter
As the liquid level gauge sprocket drive sheave rotates with liquid level changes, the motion
turns the transmitter drive shaft. The drive shaft is coupled to a worm gear that drives the shaft
of a potentiometer. Rotation causes the current in the instrumentation output loop of the
transmitter to vary. The current loop variations are carried through a conductor pair (two wires)
to a central receiver or indicator to provide the signal to an instrument that is calibrated to
remotely display the level of the fluid in the tank as it is shown on the gaugehead at the tank.
An increase in current normally indicates a rising liquid level. An outage (reverse) reading
current output option is available.
A typical installation of the 8200 COT consists of directly mounting it onto a 2500 ATG
gaugehead. It may also be mounted onto a gaugehead of other manufacturers.
The transmitter requires nominal electrical input of 15 – 48 volts of regulated direct current
(VDC), or 120 VAC/220 – 240 VAC. Current sensing analog instruments that measure current
ranges of either 4-20 mA or 10-50 mA signal, are required in the current instrumentation loop.
Transmitter housing
Encoder mechanism
and optional limit switches
DC voltage supply
transmitter board
part number
08-06886-2
AC voltage supply
transmitter board
part number
08-06886-1
Junction box
included with certain
options only
3/4 inch NPT
O-Ring
Cover
OR
Shaft coupling/
encoder mounting
hardware
3/4 inch NPT

Introduction
2Installation and Operations Manual

Current Output Transmitter
Varec, Inc. 3
2 Installation
2.1 Unpacking
The 8200 COT(s) are shipped fully assembled and ready for installation.
Place the shipping container on a secure bench before unpacking. Open the shipping container,
taking care not to damage the contents. Carefully remove transmitter from the shipping
container and place it on top of the bench. Inspect it for shipping damage. Report any damage
to the carrier.
2.2 Storage Prior to Installation
If the transmitter is to be stored prior to installation, it should be repacked in its shipping
container and stored in a temperature and humidity controlled environment.
Caution! This equipment should be installed only by qualified personnel familiar with the
installation instructions in this manual and in the
2500 Automatic Tank Gauge Installation
and Operations Manual
.
2.3 Mounting on Varec Gaugeheads
The 8200 COT is suitable for installation on 2500 ATG gaugeheads or on the gaugeheads of
other manufacturers. This procedure provides instructions to mount the transmitter on a
2500 ATG gaugehead, as shown in Figure 2-1 on page 4.
Instructions applicable to other tank gauges follow in later paragraphs. To install the
gaugehead, refer to the
2500 Automatic Tank Gauge Installation and Operations Manual . The
exploded view in that manual shows the mechanical relationship between this accessory and the
gaugehead.

Installation
4Installation and Operations Manual
Figure 2-1: Typical Tank Installation
Each 8200 COT requires two wires for analog signals. DC versions are loop powered while AC
versions require an additional three wires for power.
Warning! Whenever the back cover of the gaugehead is removed, stand to one side as the
last bolt is removed. If the negator motor spring is broken, the broken pieces may cause
injury when the cover is removed.
Warning! The mechanical connections between the gauge float guide cables, the float, the
tape, and the gaugehead provide a resistance to ground that is adequate for the safe
electrical drain of electrostatic charges that may accumulate in the tank and the product.
Worker activity and worker clothing may accumulate electrostatic charges on the body of a
worker. Care should be used in flammable environments to avoid the hazard.
Tape
conduit
(pipework)
Float &
guidewires
Manhole
cover
Spot
temperature
RTD
Tank gauge
and
transmitter
Power and
communications
conduit

Current Output Transmitter
Varec, Inc. 5
Figure 2-2: Typical Transmitter Mounting
1. If the gaugehead is oil filled, drain the oil, then remove the back cover of the gaugehead.
2. Remove the accessory back cover cap from the back cover of the gaugehead (see the
2500 Automatic Tank Gauge Installation and Operations Manual ).
3. Mount the transmitter in place of the cap onto the back cover of the gaugehead, using the
four hex head cap screws that attached the cover cap.
4. Install the back cover on the gaugehead, making certain that the transmitter slotted drive
coupling slot engages the pin on the gaugehead sprocket wheel. Using the field adjust knob
located at the end of the shaft, make sure the slotted drive coupling is securely engaged
with the drive pin.
5. Loosen the slotted drive coupling set screw using an Allen wrench. Set the transmitter to
the actual liquid level in the tank by rotating the field adjust knob located at the end of the
shaft. Once the level has been set, re-tighten the set screw.
6. Proceed with field wiring.
Sprocket, wheel,
and tape
Drive pin on sprocket
Gaugehead
Slotted drive coupling
Transmitter

Installation
6Installation and Operations Manual
2.4 Mounting on Alternate Gaugeheads
Typical Whessoe or Shand & Jurs (L & J) Gaugehead Mounting.
The following steps describe the typical tasks required for mounting the transmitter on a
Whessoe 2006, L & J 92020, 92006 (GPE), or alternate gaugehead. An adapter is required. Refer
to Chapter 4, Maintenance on page 21. The gaugehead is assumed to have been previously
installed on the tank. See Figure 2-2 on page 5 and perform the following steps.
1. Remove the access cover from the gaugehead.
2. Install the transmitter in place of the accessory access cover.
3. Make certain that the transmitter drive engages the gauge counter wheel.
4. Proceed with field wiring.
Note Please read the safety guidelines section before you begin.
2.5 Field Wiring
Warning! Do not apply power to the transmitter until all wiring connections have been
made and the cover of the transmitter has been replaced.
Warning! Do not apply power until the jumper settings have been checked and the
instrumentation current loop rechecked. Do not apply power in a hazardous environment
until the explosion proof case is closed.
Caution! Incorrect field wiring connections can damage the transmitter electronics and
cause system malfunctions. Note difference between user-furnished and on-board power.
Figure 2-3 on page 7 illustrates typical field wiring for a transmitter installation with an on-
board power supply.
Each transmitter has a two-conductor signal cable back to the control room. If AC power is
required, an additional three-conductor cable is wired to the 8200 COT, either 110 VAC or
220 – 240 VAC. Follow national and local codes for wiring of power and signal cables.

Current Output Transmitter
Varec, Inc. 7
Figure 2-3: Typical Field Wiring
2.5.1 With AC Wiring
1. Connect the (-) lead of the user power to L2.
2. Connect the (+) lead of the user power to L4.
For user-furnished DC power (loop power), see the board in Figure 2-5 on page 9.
2.5.2 User-Furnished DC Power (Loop Powered)
1. Connect the (+) lead of the user power to L2.
2. Connect the (-) lead of the user power to L4.
Note No load resistor is normally necessary if the receiving device is an analog current
sensing device operating within the jumpered range. Refer to the instructions for the device
in use.
FuelsManager
Software
8130 RTU
or
8300 TGI
4-20 mA Loops
Communications
between DCS/PLCs
for control capabilities
Tank Gauge
and
Transmitter
Power
Loop
Communications
Field
Control Room
/Signal

Installation
8Installation and Operations Manual
2.6 Jumper Settings
Two sets of jumpers provide the user the selection of the current output ranges and input
voltage ranges. If the optional Varec on-board 110/220 power supply is used, the VAC selection
must be made. The two AC jumpers must both be set to the applied AC voltage, 110 VAC or 220
VAC. For user-supplied DC power, only the current output range needs to be selected.
Figure 2-4: AC Supply Jumper Setting
AC Version (08-06886-1)
110/220 VAC input voltage jumpers
(Setting for 110 VAC shown)
G
N
L
L2
L4
Field Wiring
AC Electrical Connections

Current Output Transmitter
Varec, Inc. 9
Check that the 4-20/10-50 jumper is set for the current output range of the instrument load
loop that is to be used.
Figure 2-5: Current Output Jumper Setting
Current output range
jumper settings
(setting for 4-20 mA range shown)
DC Version (08-06886-2)
No parts installed in this area
L2
L4
Field Wiring

Installation
10 Installation and Operations Manual
2.7 AC Electrical Connections
Connect 110 VAC or 220 – 240 VAC (50/60 Hz) at TB3, terminals N, H and Ground. The wire
color code shown is NEC color coding in the U.S.A. and will vary in other countries. Please
reference the local electrical code.
• Black (H) = Hot
• White (N) = Neutral
• Green = Ground
2.8 Signal and Switch Wiring Color Codes
The wiring color coding is standard regardless of the model option.
• Red = L2
• Gray = L4
• Brown = Limit switch common
• Orange = Switch #1 NC
• Violet = Switch #2 NC
• Yellow = Switch #3 NC
• Blue = Switch #4 NC

Current Output Transmitter
Varec, Inc. 11
2.9 Junction Boxes and Limit Switches
The 8200 COT is shown with optional junction box in Figure 2-6. See Figures 2-8 and
Figure 2-9 on page 13, and the accompanying tables for details regarding junction box
connections.
The 8200 COT offers two or four limit switches as options. The wiring is pre-wired Normally
Closed (N.C.). The switch has connections for N.C. and Normal Open (N.O.). All switches use one
common wire. The customer may change the connection on the switch if N.O. wiring is desired.
Figure 2-6: 8200 COT Housing with Junction Box
Figure 2-7: 8200 COT Junction Box Exploded View
Junction Box
3/4 inch NPT
Transmitter
Housing
Cover
Housing
Cover
Terminal
Block
O-Ring

Installation
12 Installation and Operations Manual
Refer to Table 2-1 on page 12 for more information on limit switch connections.
Figure 2-8: Junction Box DC Connectors
Connection Wire Color Description
1RedL2
2GrayL4
3 Brown Limit switch common
4 Orange Switch #1 NC
5 Violet Switch #2 NC
6 Yellow Switch #3 NC
7 Blue Switch #4 NC
8 - Signal reference ground
Table 2-1: Junction Box DC Limit Switch Connections
3/4 inch NPT
Transmitter
Chassis
Ground