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