IOM027FVAE0804

7532 Radar Tank Gauge

Smart transmitter for continuous and non-contact precision
level measurement. For custody transfer and inventory-control
applications with NMI and PTB approval.

Installation and
Operations Manual

www.varec.com
Varec, Inc.
5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA
Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939
 Radar Tank Gauge

Brief operating instructions

000
measured value Contrast: + or +
009 008
- + E history E dist./
reset meas value
Group E
- + E
selection
00 002 003 004 005 006 007 008 051 052 053
basic setup tank medium process empty full pipe dist./ check range of start
shape property cond. calibr. calibr. diameter meas value distance mapping mapping
+
01 - flat - unknown - standard input E input F only for D and L are - ok confirm
safety settings ceiling - <1.9 - calm (see sketch) (see sketch) bypass + displayed - too small suggestion
- stilling - 1.9 … 4 surface stilling well (see sketch) - too big or specify
well - 4 … 10 - add. agitator - unknown range
… - >10 … - manual
basic setup flange:
03 030 033 034/035 reference point
mounting tank dip table dip table of measurement
calibr. gauging mode
history reset (= 555)
04 - dip table
linearisation - auto correct.
05 dip table
extended calibr. first point corrects offset
06 further points correct linearity
output D

09 092 09A 09B

display language … … plot settings recording E
curve F
- envel. curve - single curve
- incl. FAC - cyclic
- incl. cust. map L
- 0A 0A0 0A1 0A3 0A4
diagnostics present previous reset unlock … …
error error parameter
0C 555 = History Reset = 100: unlocked
system (333 = reset customer parameters) ≠ 100: locked
parameters

Note!
This operating manual explains the installation and initial start-up for the level
transmitter measuring device. All functions that are required for a typical measuring
task are taken into account here.
In addition, the 7532 RTG provides many other functions that are not included in this
operating manual, such as optimizing the measuring point and converting the measured
values.

An overview of all device functions can be found on page 96.

A description of the device functions for the 7532 RTG can also be found on the
enclosed CD-ROM.

2 Installation and Operations Manual

Radar Tank Gauge Table of Contents

Table of Contents

1 Safety Instructions ....................................4 6 Commissioning .........................................45

1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . 4 6.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Installation, commissioning and operation . . . . 4 6.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . 4 6.3 Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6.4 Basic Setup with the VU 331 . . . . . . . . . . . . . 49
1.5 Notes on safety conventions and symbols . . . . 6 6.5 Mounting calibration with VU 331 . . . . . . . . . . 57
6.6 Basic Setup with the ToF Tool . . . . . . . . . . . . . 66
2 Identification ................................................7 6.7 Mounting calibration with the ToF Tool . . . . . . 70

2.1 Device designation . . . . . . . . . . . . . . . . . . . . . . 7 7 Maintenance ...............................................73

2.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Certificates and approvals . . . . . . . . . . . . . . . 10
2.4 Registered trademarks . . . . . . . . . . . . . . . . . . 10 8 Accessories ................................................75

3 Mounting ..................................................... 11 9 Troubleshooting .......................................77

3.1 Quick installation guide . . . . . . . . . . . . . . . . . 11 9.1 Troubleshooting instructions . . . . . . . . . . . . . . 77
3.2 Incoming acceptance, transport, storage . . . . 12 9.2 System error messages . . . . . . . . . . . . . . . . . 79
3.3 Installation Conditions . . . . . . . . . . . . . . . . . . 13 9.3 Application errors . . . . . . . . . . . . . . . . . . . . . . 81
3.4 Installation instructions . . . . . . . . . . . . . . . . . . 17 9.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.5 Post-installation check . . . . . . . . . . . . . . . . . . 24 9.5 Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Wiring ............................................................25 9.7 Software history . . . . . . . . . . . . . . . . . . . . . . . 86

4.1 Quick wiring guide . . . . . . . . . . . . . . . . . . . . . 25

4.2 Connecting the measuring unit . . . . . . . . . . . 28 10 Technical data ...........................................87
4.3 Equipotential bonding . . . . . . . . . . . . . . . . . . 30 10.1 Technical data at a glance . . . . . . . . . . . . . . . 87
4.4 Degree of protection . . . . . . . . . . . . . . . . . . . 30
4.5 Overvoltage protector . . . . . . . . . . . . . . . . . . 30
4.6 Post-connection check . . . . . . . . . . . . . . . . . . 30
11 Appendix .....................................................91
11.1 Operating menu HART (Display modul), ToF Tool
5 Operation .....................................................31 91
11.2 Operating matrix HART / Commuwin II . . . . . . 94
5.1 Quick operation guide . . . . . . . . . . . . . . . . . . 31 11.3 Description of functions . . . . . . . . . . . . . . . . . . 96
5.2 Display and operating elements . . . . . . . . . . . 34 11.4 Function and system design . . . . . . . . . . . . . . 97
5.3 Local operation . . . . . . . . . . . . . . . . . . . . . . . 37
5.4 Display and acknowledging error messages . 40
5.5 HART communication . . . . . . . . . . . . . . . . . . 41
Index .......................................................................103

IOM027FVAE0804 3
Safety Instructions Radar Tank Gauge

1 Safety Instructions

1.1 Designated use

The Varec Model 7532 Radar Tank Gauge (RTG) is a compact radar level transmitter for
the continuous, contactless measurement of liquids, pastes and sludge in stilling wells.
The device can also be freely mounted outside closed metal vessels because of its
operating frequency of about 6 GHz and a maximum radiated pulsed energy of 1mW
(average power output 1 µW). Operation is completely harmless to humans and animals.

1.2 Installation, commissioning and operation

The 7532 RTG has been designed to operate safely in accordance with current technical,
safety and EU standards. If installed incorrectly or used for applications for which it is
not intended, however, it is possible that application-related dangers may arise, e.g.
product overflow due to incorrect installation or calibration. For this reason, the
instrument must be installed, connected, operated and maintained according to the
instructions in this manual: personnel must be authorised and suitably qualified. The
manual must have been read and understood, and the instructions followed.
Modifications and repairs to the device are permissible only when they are expressly
approved in the manual.

1.3 Operational safety

Hazardous areas
Measuring systems for use in hazardous environments are accompanied by separate “Ex
documentation”, which is an integral part of this Operating Manual. Strict compliance
with the installation instructions and ratings as stated in this supplementary
documentation is mandatory.
• Ensure that all personnel are suitably qualified.
• Observe the specifications in the certificate as well as national and local regulations.

FCC-approval
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.

Caution!
Changes or modifications not expressly approved by the part responsible for
compliance could void the user’s authority to operate the equipment.

4 Installation and Operations Manual

7532 Safety Instructions

1.4 Return
The following procedures must be carried out before a transmitter is sent to Varec for
repair:
• Always enclose a duly completed “Declaration of contamination” form. Only then can
Varec transport, examine and repair a returned device.
• Enclose special handling instructions if necessary, for example a safety data sheet as
per EN 91/155/EEC.
• Remove all residue which may be present. Pay special attention to the gasket grooves
and crevices where fluid may be present. This is especially important if the fluid is
dangerous to health, e.g. corrosive, poisonous, carcinogenic, radioactive, etc.

Caution!
• No instrument should be sent back for repair without all dangerous material being
completely removed first, e.g. in scratches or diffused through plastic.
• Incomplete cleaning of the instrument may result in waste disposal or cause harm to
personnel (burns, etc.). Any costs arising from this will be charged to the operator of
the instrument.

5
Safety Instructions Radar Tank Gauge

1.5 Notes on safety conventions and symbols

In order to highlight safety-relevant or alternative operating procedures in the manual,
the following conventions have been used, each indicated by a corresponding symbol in
the margin.

Safety conventions
Symbol Meaning

A warning highlights actions or procedures which, if not performed correctly,

Warning!
will lead to personal injury, a safety hazard or destruction of the instrument

Caution highlights actions or procedures which, if not performed correctly,

Caution!
may lead to personal injury or incorrect functioning of the instrument

A note highlights actions or procedures which, if not performed correctly, may

Note! indirectly affect operation or may lead to an instrument response which is not
planned

Explosion protection
Device certified for use in explosion hazardous area
0 If the 7532 RTG has this symbol embossed on its name plate it can be
installed in an explosion hazardous area

Explosion hazardous area

Symbol used in drawings to indicate explosion hazardous areas.
- – Devices located in and wiring entering areas with the designation
“explosion hazardous areas” must conform with the stated type of
protection

Safe area (non-explosion hazardous area)

Symbol used in drawings to indicate, if necessary, non-explosion
. hazardous areas.
– Devices located in safe areas still require a certificate if their outputs run
into explosion hazardous areas.

Electrical symbols
Direct voltage
% A terminal to which or from which a direct current or voltage may be
applied or supplied

Alternating voltage
& A terminal to which or from which an alternating (sine-wave) current
or voltage may be applied or supplied

Grounded terminal
) A grounded terminal, which as far as the operator is concerned, is
already grounded by means of an earth grounding system

Protective grounding (earth) terminal

* A terminal which must be connected to earth ground prior to making
any other connection to the equipment

Equipotential connection (earth bonding)

+ A connection made to the plant grounding system which may be of
type e.g. neutral star or equipotential line according to national or
company practice

6 Installation and Operations Manual

7532 Identification

2 Identification

2.1 Device designation

2.1.1 Nameplate and Certification Plates

The following technical data are given on the instrument nameplate:

7500RTG_nameplate_label.eps
Figure 1: Information on the nameplate of the 7500 RTG (example)

7500RTG_NMI_label.eps
Figure 2: Information on the NMi type plate for custody transfer applications of the
7500 RTG (example)

7500RTG_ATEX-PTB_label.eps

Figure 3: Information on the PTB type plate for custody transfer applications of the
7500 RTG (example)

7
Identification Radar Tank Gauge

2.1.2 Ordering structure

Ordering structure 7532 RTG

10 Certificates Basic weight

A For non-hazardous areas 6.5 kg
S FM IS - Class I, Division 1, Group A-D
U CSA IS - Class I, Division 1, Group A-D
1 ATEX II 1/2 G EEx ia IIC T6, note safety instruction (XA) for electrostatic charg-
ing!
Y Special version

20 Antenna type Additional

weight
Type Size Material Sealing
A Planar antenna DN150 / 6" SS316L FKM inside
B Planar antenna DN150 / 6" SS316L HNBR inside
E Planar antenna DN250 / 10" SS316L FKM inside
F Planar antenna DN250 / 10" SS316L HNBR inside 2.1 kg
U Planar antenna DN200 / 8" SS316L FKM inside
V Planar antenna DN200 / 8" SS316L HNBR inside 1.1 kg
W Planar antenna DN300 / 12" SS316L HNBR inside
X Planar antenna DN300 / 12" SS316L FKM inside 2.5 kg
Y Special version

30 Process connection
Flange Dia/Pressure Standard Material
AVJ 6"/150 lbs / RF ANSI B16.5 316/316L 11.4 kg
A3J 8"/150 lbs / RF ANSI B16.5 316/316L 19.6 kg
A5J 10"/150 lbs / RF ANSI B16.5 316/316L 28.8 kg
AWJ 6"/300 lbs / RF ANSI B16.5 316/316L 20.9 kg
AXJ 8"/300 lbs / RF ANSI B16.5 316/316L 34.3 kg
A7J 12"/150 lbs / RF ANSI B16.5 316/316L 43.2 kg
CWJ DN150 PN10 / 16 C EN 1092,1, B11) 316L 10.6 kg
CXJ DN200 PN16 C EN 1092,1, B11) 316L 16.5 kg
CZJ DN200 PN25 C EN 1092,1, B11) 316L 22.7 kg
C1J DN150 PN25 C EN 1092,1, B11) 316L 14.7 kg
C6J DN250 PN16 C EN 1092,1, B11) 316L 25.6 kg
C8J DN300 PN16 C EN 1092,1, B11) 316L 36.1 kg
XXJ with flange hub 316L
XVU Varec UNI-Flange 6"/ 304/1.4301 3.5 kg
DN150/150A,
max. 14.5LBS/PN1/1K,
compatible with:
- 6" 150LBS
- DN150 PN16
- 10K 150A
X3U Varec UNI-Flange 8"/ 304/1.4301 5.2 kg
DN200/200A,
max. 14.5LBS/PN1/1K,
compatible with:
- 8" 150LBS
- DN200 PN16
- 10K 200A
X5U Varec UNI-Flange 10"/ 304/1.4301 7.5 kg
DN250/250A,
max. 14.5LBS/PN1/1K,
compatible with:
- 10" 150LBS
- DN250 PN16
- 10K 250A
X7U Varec UNI-Flange 12"/ 304/1.4301 10.8 kg
DN300/300A,
max. 14.5LBS/PN1/1K,
compatible with:
- 12" 150LBS
- DN300 PN16
- 10K 300A
1) agreeable to DIN2527 Form C
YY9 Special version

8 Installation and Operations Manual

7532 Identification

40 Output and operation

A 4…20 mA HART with VU 331, 4-line alphanumeric dis-
play
Y Special version

50 Housing
C Aluminium T12-housing with separate connection compartment, coated, IP65
Y Special version

60 Gland / Entry
2 M20x1.5 cable gland
4 ½ NPT cable entry
9 Special version

70 Custody transfer approvals

A NMi, PTB type and test rig approval,
weights&measures approved (< 1 mm)
R Inventory Control Version,
not weights&measures approved (3 mm)
Y Special approval for custody transfer

80 Additional options
A Without additional options
Y Special version

7532- Complete product designation

9
Identification Radar Tank Gauge

2.2 Scope of delivery

Caution!
It is essential to follow the instructions concerning the unpacking, transport and storage
of measuring instruments given in the section “Incoming acceptance, transport, storage”
on page 12.

The scope of delivery consists of:

• Assembled instrument
• ToF Tool (operating program)
• Accessories (Chapter 8)

Accompanying documentation:
• Short manual (basic equalization/troubleshooting): housed in the instrument
• Operating manual (this manual)
• Operating manual: Description of the instrument functions
• Approval documentation: if this is not included in the operating manual.

2.3 Certificates and approvals

CE mark, declaration of conformity
The instrument is designed to meet state-of-the-art safety requirements, has been
tested and left the factory in a condition in which it is safe to operate. The instrument
complies with the applicable standards and regulations in accordance with EN 61010
“Protection Measures for Electrical Equipment for Measurement, Control, Regulation and
Laboratory Procedures”. The instrument described in this manual thus complies with the
statutory requirements of the EG directives. Varec confirms the successful testing of the
instrument by affixing to it the CE mark.

2.4 Registered trademarks

KALREZ ®, VITON ®, TEFLON ®
Registered trademark of the company E.I. Du Pont de Nemours & Co., Wilmington, USA

TRI-CLAMP ®
Registered trademark of the company Ladish & Co., Inc., Kenosha, USA

HART ®
Registered trademark of HART Communication Foundation, Austin, USA

ToF ®
Registered trademark of the company Endress+Hauser GmbH+Co. KG, Maulburg, Ger-
many

PulseMaster ®
Registered trademark of the company Endress+Hauser GmbH+Co. KG, Maulburg, Ger-
many

PhaseMaster ®
Registered trademark of the company Endress+Hauser GmbH+Co. KG, Maulburg, Ger-
many

10 Installation and Operations Manual

7532 Mounting

3 Mounting

3.1 Quick installation guide

Installation only in stilling well:

Turn housing
The housing can be turned
in order to simplify access to the
display and the terminal compartment

T12 housing
2
˚
90

The performance of the 7532 RTG Allen key

4 mm
planar antenna is not dependent on the . tighten strongly
alignment or geometry of standard stilling by hand
wells.
No special alignment is required.
However, make sure that the planar
antenna is installed vertically relative
to the stilling well axis.
.

L00-FMR532xx-17-00-00-en-002

Note!
The 7532 RTG with planar antenna is designed for use on stilling-wells only!

11
Mounting Radar Tank Gauge

3.2 Incoming acceptance, transport, storage

3.2.1 Incoming acceptance

Check the packing and contents for any signs of damage.
Check the shipment, make sure nothing is missing and that the scope of supply matches
your order.

3.2.2 Transport

Caution!
Follow the safety instructions and transport conditions for instruments of more than
18 kg. Do not lift the measuring instrument by its housing in order to transport it.

3.2.3 Storage
Pack the measuring instrument so that is protected against impacts for storage and
transport. The original packing material provides the optimum protection for this.
The permissible storage temperature is -40 °C…+80 °C.

12 Installation and Operations Manual

7532 Mounting

3.3 Installation Conditions

3.3.1 Dimensions

68 (2.68") 94 (3.7") 65 (2.56") 85 (3.35")

Ø 129 (5.08")
ENDRESS+HAUSER
Micropilot II

238 (9.37")
8 (0.31")
DIN, ANSI, E+H UNI flange
JIS (max. 1 bar)

93 (3.66")

inactive length
(2.36")
detail A:

60
flange adapter

(1.18")
(see under)

30
Ø 150 (5.91")

DN150 / 6”
L

version without widening

DN200…300 / 8…12”
version with
antenna widening
detail A
flange hub for the connection
to flanges provided by the customer
mounting:
Ø 78 (3.07") 4 bolts M6 / 90°
e.g. DIN 912
Ø 62,5 (2.46")
ØD
O-Ring 85.3 x 3.53,
included
(same material as
sensor seal)

L00-FMR532xx-06-00-00-en-001
(0.35")
9
flange hub

Ø 99,5 (3.92")

Figure 4: Dimensions 7532 RTG

Antenna version DN150 / 6" DN200 / 8" DN250 / 10" DN300 / 12"
L [mm] 93 337 490 517
Ø D [mm] no horn 190 240 290

Note!
The inactive length of 60 mm prevents condensation effects to the antenna perfor-
mance. Special versions with longer construction are available.

13
Mounting Radar Tank Gauge

3.3.2 Engineering tips

Measuring conditions
• The measuring range starts at the bottom end of the stilling well.
• In case of media with a low dielectric constant (groups A and B), the pipe end can be
visible through the medium at low levels. In order to guarantee the required accuracy
in these cases, it is recommended to position the zero-point at a distance C above the
tank bottom (see Fig.).
• In applications with planar or parabolic antennas, especially for media with low
dielectric constants (see page 15), the end of the measuring range should not be closer
than 1 m (40”) to the flange.
• For overspill protection, it is possible to define a safety distance (SD) additionally to
the blocking distance (BD).
• This safety distance (SD) is set to 0.5 m (20") by default and generating an alarm in
case the level rises inside the safety distance.
• Distance B defined the smallest recommended measurement range.
• Depending on its consistence, foam can either absorb microwaves or reflect them off
the foam surface. Measurement is possible under certain conditions.

100% BD
A

SD
max. level

L00-FMR53xxx-17-00-00-en-008
C
0%

reference: flange / BD reference: antenna tip

(see picture) (see picture)
Blocking Safety
recommended additional settings
distance distance
BD [m / ft] SD [m / ft] A [mm / inch] B [m / ft] C [mm / inch]
150…300 /
7532 RTG (planar) 1 / 3.28 0.5 / 1.6 1000 / 40 0.5 / 1.64
6…12

Behaviour if measuring range is exceeded

The behaviour in case of the measuring range being exceeded can be freely set: the
default setting is a current of 22 mA and the generation of a digital warning (E681).

14 Installation and Operations Manual

7532 Mounting

Measuring range
The usable measuring range depends on the size of the antenna, the reflectivity of the
medium, the mounting location, and eventual interference reflections.
The following tables describe the groups of media as well as the achievable measuring
range as a function of application and media group. If the dielectric constant of a
medium is unknown, it is recommended to assume media group B to ensure a reliable
measurement.

Product class DK (εr) Examples

A 1.4 … 1.9 non-conducting liquids, e.g. liquefied gas 1)

B 1.9 … 4 non-conducting liquids, e.g. benzene, oil, toluene, …

C 4 … 10 e.g. concentrated acids, organic solvents, esters, aniline,

alcohol, acetone, …

D > 10 conducting liquids, e.g. aqueous solutions, dilute acids and

alkalis

1)Treat Ammonia NH3 as a medium of group A, e.g. always use a stilling well.

Measuring range depending on product class for 7532 RTG:

Product class Stilling well/ Bypass

Measuring range

7532 RTG
> DN150

A DK(εr)=1,4…1,9 38 m/124 ft

B DK(εr)=1,9…4 38 m/124 ft

C DK(εr)=4…10 38 m/124 ft

D DK(εr)>10 38 m/124 ft

max. measuring
range with custody 20 m/65 ft
transfer approvals

15
Mounting Radar Tank Gauge

Blocking distance
The blocking distance (= BD) is the minimum distance from the reference point of the
measurement (mounting flange) to the medium surface at maximum level.

reference point of
measurement

L00-FMR53xxx-15-00-00-en-003
BD
20 mA
Max. 100%
Level

Blocking distance Stilling well / Bypass

(BD)
7532 RTG

from Flange 1 m/40"

Note!
Inside the blocking distance a reliable measurement can not be guaranteed.

16 Installation and Operations Manual

7532 Mounting

3.4 Installation instructions

3.4.1 Mounting kit

In addition to the tool needed for flange mounting, you will require the following tool:
• 4 mm Allen wrench for turning the housing.

3.4.2 Installation in stilling well

Optimum mounting position for 7532 RTG

Standard installation
When mounting in the stilling well, please
observe engineering tips on page 14 and
the following points:
• After mounting, the housing can be
turned 350° in order to simplify access to
the display and the terminal
compartment.
• planar axis vertical to flange.
• Measurements can be performed
through an open ball valve without any

L00-FMR532xx-17-00-00-en-003
problems.

Recommendations for the stilling well

• Metal (no enamel coating, plastic on request).
• Constant diameter.
• Weld seam as smooth as possible and on the same axis as the slots.
• Slots offset 180° (not 90°).
• Slot width respectively diameter of holes max. 1/10 of pipe diameter, de-burred.
Length and number do not have any influence on the measurement.

• Select antenna extension as big as possible. For intermediate sizes (e.g. 180 mm)
select next larger antenna extension and adapt it mechanically. Maximum gap allowed
between the antenna/horn of 7532 RTG and the inside of the stilling well is 5 mm (3/
16").
• The antennna extension of the 7532 RTG is mounted with defined pressure.
It is strongly recommended not to dismantle this antenna.
• Dimensions of a nozzle for manual gauging must be adapted to the dimensions of
the horn antenna used, compare to page page 23.

Stilling wells with pipe expansion

• When using a 7532 RTG, a gradual pipe expansion from DN150 to DN200 / DN200
to DN250 / DN250 to DN300 is acceptable. In such cases, the top end of the piping
must have a minimum length of 0.5 m in front of the expansion (see table on page 18).
Ideally, a dip socket is used for this.
• Greater expansion of the piping (e.g. DN150 to DN300) is possible if the top end of
the pipe is extended accordingly (see table on page 18).
• Avoid pipe expansions at right angles.

17
Mounting Radar Tank Gauge

Examples for the construction of stilling wells

7532 RTG

7532 RTG

L00-FMR532xx-17-00-00-en-004

18 Installation and Operations Manual

7532 Mounting

3.4.3 Turn housing

After mounting, the housing can be turned 350° in order to simplify access to the display
and the terminal compartment. Proceed as follows to turn the housing to the required
position:
• Undo the fixing screws (1)
• Turn the housing (2) in the required direction
• Tighten up the fixing screws (1)

T12 housing
2

L00-FMR532xx-17-00-00-en-005
Allen key
4 mm
tighten strongly
by hand

19
Mounting Radar Tank Gauge

3.4.4 Installation with Varec UNI flange

Installation tips
Varec UNI flanges are designed for non-pressurized operation respectively max. 1 bar
absolute pressure. The number of bolts has sometimes been reduced. The bolt-holes
have been enlarged for adaption of dimensions, therefore, the flange needs to be
properly aligned to the counterflange before the bolts are tightened.

L00-FMR53xxx-06-00-00-en-001

Version Compatible with D [mm] K [mm] Type plate no.

1000 DN150 PN16 280 240 942455-3001
ANSI 6" 150lbs
JIS 10K 150
2000 DN200 PN16 340 294.5 942455-3002
ANSI 8" 150lbs
JIS 10K 200
3000 DN250 PN16 405 358 942455-3003
ANSI 10" 150lbs
JIS 10K 250
4000 DN300 PN16 482 410 (for DIN), 431,8 942455-3004
ANSI 12" 150lbs (for ANSI), 400 (for
JIS 10K 300 JIS),
404,5 (for DIN + JIS)

20 Installation and Operations Manual

7532 Mounting

Preparation for the installation of the Varec UNI flange

R532xx-00-00-06-en-002

21
Mounting Radar Tank Gauge

16 pull off housing

17 mount Varec UNI flange

Varec UNI flange

(max. 1 bar)

detail A:
flange adapter
(see under)

detail A
flange hub for the connection
to flanges provided by the customer
mounting:
Ø 78 4 bolts M6 / 90˚
e.g. DIN 912
Ø 62.5
O-Ring 85.3 x 3.53,
included
(same material as
sensor seal)

L00-FMR532xx-00-00-06-en-003
9

flange hub

Ø 99.5

22 Installation and Operations Manual

7532 Mounting

3.4.5 Mounting with Sample hatch on stilling well

Installation tips
For control and cleaning purposes as well as for hand dipping (tape), a sample hatch
gauging is recommended. The sensor head can be easily checked in the area of the
opening. Manual gauging with gauge rod or tape is possible without removal of the
transmitter. The lower edge of the opening is the reference for the gauging. The
construction is only suitable for non-pressurized operation.

Note!
The nozzle for manual gauging is not part of the standard offering from Varec. Please
contact Varec for further information.

L00-FMR53xxx-06-00-00-en-004
Flange DN150 DN200 DN250/300 Flange ANSI 6" ANSI 8" ANSI 10"
PN [lbs] 2)
16 16 16 PN [lbs] 2)
150 150 150
A [mm] 110 140 170 A [mm] 110 140 170
L [mm} — 300 450 L [mm] — 300 450
2)Only dimensions adapted to standard. Designed for non-pressurized operation only,
therefore thickness of flange can be reduced (e.g. 8mm).

23
Mounting Radar Tank Gauge

3.4.6 Mounting with Pivoting element

Installation tips
The Pivoting element serves to swivel the 7500 RTG from the measuring position, e.g.
to clean the antenna or dip the tank.
The pivoting element is not part of the standard offering from Varec, special offers
available under ref. number MVTFM0422.

L00-FMR53xxx-17-00-00-en-013

3.5 Post-installation check

After the measuring instrument has been installed, perform the following checks:
• Is the measuring instrument damaged (visual check)?
• Does the measuring instrument correspond to the measuring point specifications
such as process temperature/pressure, ambient temperature, measuring range, etc.?
• Is the flange marking correctly aligned? (see page 11)
• Have the flange screws been tightened up with the respective tightening torque?
• Are the measuring point number and labeling correct (visual check)?
• Is the measuring instrument adequately protected against rain and direct sunlight
(see page 75)?

24 Installation and Operations Manual

7532 Wiring

4 Wiring

4.1 Quick wiring guide

When grounding conductive screens, the corresponding directives EN 60079-14 and EN
1127-1 must be observed. Recommendation for safe grounding of conductive screens:

Wiring

25
Wiring Radar Tank Gauge

"
Caution!
Before connection please note the following:
● The power supply must be identical to the data on the
nameplate (1).
● Switch off power supply before connecting up the device. 1
● Connect Equipotential bonding to transmitter ground terminal
before connecting up the device.
● Tighten the locking screw:
It forms the connection between the antenna and the housing
ground potential. 2

When you use the measuring system in hazardous areas, make sure you comply with
national standards and the specifications in the safety instructions (XA’s).
Make sure you use the specified cable gland.

Connect up the 7500 RTG as follows:

- Before unscrew housing cover (2) at seperate connection room

turn off the power supply!
● Insert cable through gland (3).
Use screened, twisted wire pair.

- Only ground screening of the line (5) on sensor side.

● Make connection (see pin assignment).

● Tighten cable gland (4).
● Screw off housing cover (2).
● Switch on power supply. 4

power: signal:
24 VDC 24 VDC
(16…30 V)

1 2 3 4

plant
1 2 3 4 5 ground

1 2 3 4 5

A 7500 RTG situated in a hazardous area is connected as a single

device to a power supply unit and transmitter situated outside of
the hazardous area. In this case, it is recommended that the screen
75xx_wiring.eps

be connected directly to the 7500 RTG at the housing's earth,

whereby the 7500 RTG and the power supply unit are connected to
the same potential matching line (PML).

26 Installation and Operations Manual

7532 Wiring

Wiring with Tank Side Monitor 4590

"
Caution!
Before connection please note the following:
● The power supply must be identical to the data on the
nameplate (1).
● Switch off power supply before connecting up the device. 1

● Connect Equipotential bonding to transmitter ground terminal

before connecting up the device.
● Tighten the locking screw: 2
It forms the connection between the antenna and the housing
ground potential.

When you use the measuring system in hazardous areas, make sure you comply with
national standards and the specifications in the safety instructions (XA’s).
Make sure you use the specified cable gland.

Connect up the 7500 RTG as follows:

- Before unscrew housing cover (2) at seperate connection room

turn off the power supply!
● Insert cable through gland (3).
Use screened, twisted wire pair.
● Make connection (see pin assignment).
● Tighten cable gland (4).
● Screw off housing cover (2).
Tank Side Monitor
4590 TSM ● Switch on power supply.

intrinsicaly safe
terminal
NRF 590 i.s. terminal board board

D+ RTD
16
S+
17
S-
18
D-
19

20 OPT1
21 OPT2 grounding single sided grounding not on
i.s. module wiring 7500 RTG
22 OPT3 on Tank Side Monitor
23 OPT4 4590 TSM
+
24 H
25 - 1 2 3 4
+ Internally
26 HART interconnected
H
27 - sensor as one HART
fieldbus loop
+ + plant
28 4
29
30
-H
+
P
- 3
+
2
1 2 3 4 5 ground

31 - - 1 1 2 3 4 5

For Micropilot
only for
S-series only!
7500 RTG
75xx_wiring_w_TSM.

The 7500 RTG is - possibly in combination with other devices - connected to a Tank
Side Monitor in a hazardous area. In this case, it is recommended that you ground
the cable screen centrally at the Tank Side Monitor and connect all devices to the
same potential matching line (PML). If, for functional reasons, a capacitive coupling is
required between local earth and screen (multiple grounding), ceramic condensers
with a dielectric strength of min. 1500 Veff must be used, whereby the total capacitance
of 10 nF must not be exceeded. Notes on grounding interconnected intrinsically safe
devices are provided by the FISCO model

27
Wiring Radar Tank Gauge

4.2 Connecting the measuring unit

Terminal compartment
The housing comes with a separate terminal compartment.

L00-FMR53xxx-04-00-00-en-001
Load HART
Minimum load for Hart communication: 250 Ω

Cable entry
Cable gland: M20x1.5 or Pg13.5
Cable entry: G ½ or ½ NPT

Supply voltage
Direct current voltage: 16…36 VDC
.
Communication Terminal voltage minimal maximal

Power supply Standard U (20 mA) = 16 V 36 V

Ex U (20 mA) = 16 V 30 V

Signal U (4 mA) = 11,5 V 30 V

Ex
U (20 mA) = 11,5 V 30 V

Power consumption
Max. 330 mW at 16 V, max. 500 mW at 24 V, max. 600 mW at 30 V.

Current consumption
Max. 21 mA (50 mA inrush current).

Power supply
For stand alone operation recommended via e.g. Varec RN 221N.

mm accuracy
For measurements with mm accuracy the measured variable must be transmitted
using HART protocol to ensure the necessary resolution.

28 Installation and Operations Manual

7532 Wiring

4.2.1 Connection to Tank Side Monitor 4590

See page 27.

4.2.2 HART connection with two Varec RN 221 N

- ToF Tool

FXA 193

RN 221N
power supply

4...20 mA
signal

L00-FMR53xxx-04-00-00-en-004
dsdmdm
df das.
asdas fa
asas la.

DELTABAR: * * * * * * * *
ONLINE
1 QUICK SETUP
2 OPERATING MENU
3 PV 352 mbar
4 SV 0 ˚C

HELP SAVE

1 2 3 4 5
9 Page
Up
6 - COMMUWIN II
- ToF Tool
Bksp Delete

Page
On

#%& ABC DEF

1 2 3
Copy Paste Hot Key

GHI JKL MNO

4 5 6
Insert + Hot Key

PQRS TUV W XY Z
7 8 9
,()‘ _<> +*/
. 0 -

HART
375
FIELD COMMUNICATOR

HART handheld Commubox

DXR 375 FXA 191

4.2.3 HART connection with other supplies

- ToF Tool

FXA 193 DC voltage

or
power supply PLC

4...20 mA
signal
≥ 250 Ω
L00-FMR53xxx-04-00-00-en-005

dsdmdm
df das.
asdas fa
asas la.

DELTABAR: * * * * * * * *
ONLINE
1 QUICK SETUP
2 OPERATING MENU
3 PV 352 mbar
4 SV 0 °C

HELP SAVE

1 2 3 4 5
9 Page
Up
6 - COMMUWIN II
- ToF Tool
Bksp Delete

Page
On

#%& ABC DEF

1 2 3
Copy Paste Hot Key

GHI JKL MNO

4 5 6
Insert + Hot Key

PQRS TUV W XY Z
7 8 9
,()‘ _<> +*/
. 0 -

HART
375
FIELD COMMUNICATOR

HART handheld Commubox

DXR 375 FXA 191

Caution!
If the HART communication resistor is not built into the supply unit, it is necessary to
insert a communication resistor of 250 Ω into the 2-wire line.

29
Wiring Radar Tank Gauge

4.3 Equipotential bonding

Connect the Equipotential bonding to the external ground terminal of the transmitter.

Caution!
In Ex applications, the instrument must only be grounded on the sensor side. Further
safety instructions are given in the separate documentation for applications in explosion
hazardous areas.

4.4 Degree of protection

• housing: IP 65, NEMA 4X (open housing: IP20, NEMA 1)
• antenna: IP 68 (NEMA 6P)

4.5 Overvoltage protector

• The level transmitter 7500 RTG is equipped with an internal overvoltage protector
(600 Vrms electrode). Connect the metallic housing of the 7500 RTG to the tank wall
directly with an electrically conductive lead to ensure reliable potential matching.
• Installation with additional overvoltage protector HAW 262 Z (see XA 081F-A
"Safety instructions for electrical apparatus certified for use in explosion-hazardous
areas").
–Connect the external overvoltage protector and the 7500 RTG transmitter to the local
potential matching system.
–Potentials shall be equalised both inside and outside the explosion hazardous area.
–The cable connecting the overvoltage protector and the 7500 RTG transmitter shall
not exceed 1 m in length;
–The cable shall be protected e.g. routed in an armoured hose.

4.6 Post-connection check

After wiring the measuring instrument, perform the following checks:
• Is the terminal allocation correct (see page 25)?
• Is the cable gland tight?
• Is the housing cover screwed tight?
• If auxiliary power is available:
Is the instrument ready for operation and does the liquid crystal display show any
value?

30 Installation and Operations Manual

7532 Operation

5 Operation

5.1 Quick operation guide

31
Operation Radar Tank Gauge

– + E
X

F
2x X
X X >3 s

F F ...
O
O O

...
S S
S ...

Selection and configuration in Operation menu:

1.) Change from Measured Value Display to Group Selection by pressing F
2.) Press S or O to select the required Function Group (e.g.. "basic setup (00)") and confirm by pressing
F ➜ First function (e.g. "tank shape (002)") is selected.
Note!
The active selection is marked by a in front of the menu text.
3.) Activate Edit mode with O or S.
Selection menus:
a) Select the required Parameter in selected function (e.g. "tank shape (002)") with S or O.
b) F confirms selection ➜ appears in front of the selected parameter
c) F confirms the edited value ➜ system quits Edit mode
d) O + S (= X) interrupts selection ➜ system quits Edit mode
Typing in numerals and text:
a) Press O or S to edit the first character of the numeral / text (e.g. "empty calibr. (005)")
b) F positions the cursor at the next character ➜ continue with (a) until you have completed your input
c) if a symbol appears at the cursor, press F to accept the value entered
➜ system quits Edit mode
L00-FMR2xxxx-19-00-00-en-001

d) O + S (= X) interrupts the input, system quits Edit mode

4) Press F to select the next function (e.g. "medium property (003)")
5) Press O + S (= X) once ➜ return to previous function (e.g. "tank shape (002)")
Press O + S (= X) twice ➜ return to Group selection
6) Press O + S (= X) to return to Measured value display

32 Installation and Operations Manual

7532 Operation

5.1.1 General structure of the operating menu

The operating menu is made up of two levels:
• Function groups (00, 01, 03, …, 0C, 0D):
The individual operating options of the instrument are split up roughly into different
function groups. The function groups that are available include, e.g.: "basic setup",
"safety settings", "output", "display", etc.
• Functions (001, 002, 003, …, 0D8, 0D9):
Each function group consists of one or more functions. The functions perform the
actual operation or parameterization of the instrument. Numerical values can be
entered here and parameters can be selected and saved. The available functions of the
“basic setup (00)” function group include, e.g.: "tank shape (002)",
"medium property (003)", "process cond. (004)", "empty calibr. (005)", etc.

If, for example, the application of the instrument is to be changed, carry out the follow-
ing procedure:

1.Select the “basic setup (00)” function group.

2.Select the "tank shape (002)" function (where the existing tank shape is selected).

5.1.2 Identifying the functions

For simple orientation within the function menus (see page 91), for each function a
position is shown on the display.

L00-FMR2xxxx-07-00-00-en-005
The first two digits identify the function group:
• basic setup 00
• safety settings 01
• linearization 04
…
The third digit numbers the individual functions within the function group:
• basic setup 00 → • tank shape 002
• medium property 003
• process cond. 004
…
Here after the position is always given in brackets (e.g. "tank shape" (002)) after the
described function.

33
Operation Radar Tank Gauge

5.2 Display and operating elements

L00-FMR53xxx-07-00-00-en-003
Figure 5: Layout of the display and operating elements

5.2.1 Display
Liquid crystal display (LCD):
Four lines with 20 characters each. Display contrast adjustable through key
combination.

Headline Position indicator

Symbol Main value Bargraph Unit

– + E

Selection list
L00-FMRxxxxx-07-00-00-en-003

Help text

Envelope
curve

Figure 6: Display

34 Installation and Operations Manual

7532 Operation

5.2.2 Display symbols

The following table describes the symbols that appear on the liquid crystal display:

Symbols Meaning

ALARM_SYMBOL
This alarm symbol appears when the instrument is in an alarm state. If the symbol
flashes, this indicates a warning.

LOCK_SYMBOL
This lock symbol appears when the instrument is locked,i.e. if no input is possible.

COM_SYMBOL
This communication symbol appears when a data transmission via e.g. HART,
PFOFIBUS-PA or Foundation Fieldbus is in progress.

Calibration to regulatory standards disturbed

If the instrument is not locked or it cannot guarantee the calibration to regulatory
standards, the situation will be indicated on the display via the symbol.

Table 1: Meaning of the symbols

Light emitting diodes (LEDs):

There is a green and a red LED besides the Liquid Crystal Display.

LED Meaning

red LED continuously on Alarm

red LED flashes Warning

red LED off No alarm

green LED continuously on Operation

Green LED flashes Communication with external device

35
Operation Radar Tank Gauge

5.2.3 Key assignment

The operating elements are located inside the housing and are accessible for operation
by opening the lid of the housing.

Function of the keys

Key(s) Meaning

Navigate upwards in the selection list

O or V Edit numeric value within a function

Navigate downwards in the selection list

S or W Edit numeric value within a function

X or Z Navigate to the left within a function group

F or M Navigate to the right within a function group, confirmation.

O and F
or Contrast settings of the LCD
S and F

Hardware lock / unlock

After a hardware lock, an operation of the instrument via display or
O and S and F communication is not possible!
The hardware can only be unlocked via the display. An unlock parameter must
be entered to do so.

Table 2: Function of the keys

Custody locking switch

Access to the electronics can be prevented by means of a custody locking switch that
locks the device settings; see fig. 4 on Page 34.
The custody locking switch can be sealed for custody transfer applications.

Software reliability
The software used in the 7500 RTG fulfills the requirements of
OIML R85. This particularly includes:
• cyclical test of data consistency
• non-volatile memory
• segmented data storage

The 7500 RTG continuously monitor the compliance with accuracy requirements for
custody transfer measurements according to OIML R85. If the accuracy cannot be
maintained, a specific alarm is generated on the local display and via the digital
communication

36 Installation and Operations Manual

7532 Operation

5.3 Local operation

5.3.1 Locking of the configuration mode

The 7500 RTG can be protected in two ways against unauthorized changing of instru-
ment data, numerical values or factory settings:

"unlock parameter" (0A4):

A value <> 100 (e.g. 99) must be entered in "unlock parameter" (0A4) in the
"diagnostics" (0A) function group. The lock is shown on the display by the symbol and
can be released again either via the display or by communication.

Hardware lock:
The instrument is locked by pressing the O and S and F keys at the same time.
The lock is shown on the display by the symbol and can only be unlocked again
via the display by pressing the O and S and F keys at the same time again. It is not
possible to unlock the hardware by communication.
All parameters can de displayed even if the instrument is locked.

– + E
⇒
⇓ O and S and F press simultaneous

⇓
The LOCK_SYMBOL appears on the LCD.

37
Operation Radar Tank Gauge

5.3.2 Unlocking of configuration mode

If an attempt is made to change parameters when the instrument is locked, the user is
automatically requested to unlock the instrument:

"unlock parameter" (0A4):

By entering the unlock parameter (on the display or via communication)

100 = for HART devices

the 7500 RTG is released for operation.

Hardware lock:
After pressing the O and S and F keys at the same time, the user is asked to enter the
unlock parameter

100 = for HART devices.

– + E
⇒ O and S and F press simultaneous

⇓
Please enter unlock code and confirm with F.

Caution!
Changing certain parameters such as all sensor characteristics, for example, influences
numerous functions of the entire measuring system, particularly measuring accuracy.
There is no need to change these parameters under normal circumstances and
consequently, they are protected by a special code known only to the Varec service
organization. Please contact Varec if you have any questions.

38 Installation and Operations Manual

7532 Operation

5.3.3 Factory settings (Reset)

Caution!
A reset sets the instrument back to the factory settings. This can lead to an impairment
of the measurement. Generally, you should perform a basic setup again following a
reset.

A reset is only necessary:

• if the instrument no longer functions
• if the instrument must be moved from one measuring point to another
• if the instrument is being de-installed /put into storage/installed

– + E
⇒
User input ("reset" (0A3)):
• 333 = customer parameters
• 555 = History

333 = reset customer parameters

This reset is recommended whenever an instrument with an unknown 'history' is to be
used in an application:
• The 7500 RTG is reset to the default values.
• The customer specific tank map is not deleted.
• A linearization is switched to "linear" although the table values are retained. The table
can be reactivated in the "linearization" (04) function group.

List of functions that are affected by a reset:

• tank shape (002) • linearization (041)
• empty calibr. (005) • customer unit (042)
• full calibr. (006) • diameter vessel (047)
• pipe diameter (007) • range of mapping (052)
• output on alarm (010) • pres. Map dist (054)
• output on alarm (011) • offset (057)
• outp. echo loss (012) • low output limit (062)
• ramp %span/min (013) • fixed current (063)
• delay time (014) • fixed cur. value (064)
• safety distance (015) • simulation (065)
• in safety dist. (016) • simulation value (066)
• Tank Gauging (030) • format display (094)
• auto correction (031) • distance unit (0C5)
• level/ullage (040) • download mode (0C8)

555 = History Reset

After mounting and aligning the equipment, carry out a history reset before switching
on the function "Auto-correction" (031) (see page 57).

The tank map can also be reset in the "cust. tank map" (055) function of the
"extended calibr." (05) function group.
This reset is recommended whenever an instrument with an unknown 'history' is to be
used in an application or if a faulty mapping was started:
• The tank map is deleted. The mapping must be recommenced.

39
Operation Radar Tank Gauge

5.4 Display and acknowledging error messages

Type of error
Errors that occur during commissioning or measuring are displayed immediately on the
local display. If two or more system or process errors occur, the error with the highest
priority is the one shown on the display.
The measuring system distinguishes between two types of error:
• A (Alarm):
Instrument goes into a defined state (e.g. MAX 22 mA)
Indicated by a constant symbol.
(For a description of the codes, see Table 9.2 on Page 79)
• W (Warning):
Instrument continue measuring, error message is displayed.
Indicated by a flashing symbol.
(For a description of the codes, see Table 9.2 on Page 79)
• E (Alarm / Warning):
Configurable (e.g. loss of echo, level within the safety distance)
Indicated by a constant/flashing symbol.
(For a description of the codes, see Table 9.2 on Page 79)

– + E
⇒
Error messages
Error messages appear as four lines of plain text on the display. In addition, a unique
error code is also output. A description of the error codes is given on page 79.
• The "diagnostics (0A)" function group can display current errors as well as the last
errors that occurred.
• If several current errors occur, use O or S to page through the error messages.
• The last occurring error can be deleted in the "diagnostics (0A)" function group
with the function "clear last error" (0A2).

40 Installation and Operations Manual

7532 Operation

5.5 HART communication

Apart from local operation, you can also parameterize the measuring instrument and
view measured values by means of a HART protocol. There are two options available for
operation:
• Operation via the universal handheld operating unit, the
HART Communicator DXR 375.
• Operation via the Personal Computer (PC) using the operating program
(e.g. ToF Tool or Commuwin II) (For connections, see page 29).
• Operation via the Tank Side Monitor 4590.

5.5.1 Handheld unit DXR 375

All device functions can be adjusted via menu operation with the handheld unit
DXR 375.

dsdmdm
df das.
asdas fa
asas la.

dsdmdm
df das.
asdas fa
asas la.
FMR531: LIC0001
FMR531: LIC0001 ONLINE
ONLINE
1 GROUP SELECTION
1 GROUP SELECT
2 PV 8.7 m 2 PV 8.7 m Delete

HELP SAVE

H dsdmdm
df das.
asdas fa
asas la.

FMR531: LIC0001
6
9
HELP SAVE
Page GROUP SELECTION
Up

1 CALIBRATION
Bksp Delete 2 LINEARISATION Delete
3 EXT. CALIBRATION
Page 4 SERVICE
On Bksp 5 OPERATING MODE
#%& ABC DEF
1 2 3

L00-FMR53xxx-07-00-00-xx-001
Copy

GHI
Paste

JKL
Hot Key

MNO
H dsdmdm
df das.
asdas fa
asas la.

4 5 6 SAVE HOME FMR531: LIC0001

Insert + Hot Key
CALIBRATION
PQRS TUV W XY Z
1 MEASURED VALUE
Page
7 8 9
2 EMPTY CALIBRATION Up
,()‘ _<> +*/ 3 FULL CALIBRATION
. 0 - 4 APPLICATION PARAMETER
Bksp 5 OUTPUT DAMPING Page
On
375
FIELD COMMUNICATOR
SAVE HOME

Figure 7: Menu operation with the DXR 375 handheld instrument

Note!
• Further information on the HART handheld unit is given in the respective operating
manual included in the transport bag of the instrument.

5.5.2 ToF Tool operating program

The ToF Tool is a graphical operating software for instruments from Varec that operate
based on the time-of-flight principle. It is used to support commissioning, securing of
data, signal analysis and documentation of the instruments. It is compatible with the
following operating systems: Win95, Win98, WinNT4.0, Win2000 and
Windows XP.
The ToF Tool supports the following functions:
• Online configuration of transmitters
• Signal analysis via envelope curve
• Loading and saving of instrument data (Upload/Download)
• Documentation of measuring point

41
Operation Radar Tank Gauge

Note!
Further information you may find on the CD-ROM, which is enclosed to the instrument.

Menu-guided commissioning

Signal analysis via envelope curve

Connection options:
• Service-interface with adapter FXA 193 (see page 29)
• HART with Commubox FXA 191 (see page 29)

42 Installation and Operations Manual

7532 Operation

5.5.3 Commuwin II-Operating Program

Commuwin II is an operating software with graphical support for intelligent transmitters
with the communication protocols Rackbus, Rackbus RS 485, INTENSOR, HART or
PROFIBUS-PA. It is compatible with the operating systems Win 3.1/3.11, Win95, Win98
and WinNT4.0. All functions of Commuwin II are supported. The configuration is made
via operating matrix or graphic surface. A envelope curve can be displayed in ToF Tool.

Note!
Further information on Commuwin II is given in the following Varec documentation:
• System Information: SI 018F/00/en “Commuwin II”
• Operating Manual: BA 124F/00/en “Commuwin II” operating program

Connection
The table provides an overview of the Commuwin connections.
Interface Hardware Server Device list
HART Commubox FXA 191 to HART HART Connected instrument
Computer with RS-232C interface
Interface FXN 672 ZA 673 for List of all rack bus modules:
Gateway for MODBUS, PROFIBUS, PROFIBUS the required FXN 672 must
FIP, INTERBUS, etc. ZA 672 for be selected
Computer with other
RS-232C interface or
PROFIBUS card

Note!
The 7500 RTG can also be operated locally using the keys. If operation is prevented by
the keys being locked locally, parameter entry via communication is not possible either.

43
Operation Radar Tank Gauge

44 Installation and Operations Manual

7532 Commissioning

6 Commissioning

6.1 Function check

Make sure that all final checks have been completed before you start up your measuring
point:
• Checklist “Post installation check” (see page 24).
• Checklist “Post connection check” (see page 30).

6.2 Commissioning

6.2.1 Switching on the measuring device

When the instrument is switched on for the first time, the following messages appear on
the display:

– + E
⇒
⇓ After 5 s, the following message appears

⇓
After 5 s or after you have pressed F the follow-
ing message appears

Select the language

(this message appears the first time the instrument
is switched on)

⇓
Select the basic unit
(this message appears the first time the instrument
is switched on)

⇓
The current measured value is displayed

⇓ After F is pressed, you reach the group selection.

This selection enables you to perform the basic

setup

45
Commissioning Radar Tank Gauge

6.3 Basic Setup

46 Installation and Operations Manual

7532 Commissioning

Commissioning
flange:
reference point of
measurement

BD

measuring cond.
SD
D
basic setup (standard)

measuring cond.

empty calibr. F

full calibr. L

pipe diameter
(for bypass/stilling well)

E = empty calibr. (= zero) F = full calibr. (= span)

settings in 005 settings in 006
mapping D = distance (distance flange / product) L = level
display in 0A5 display in 0A6
SD = safety settings BD = blocking dist.
settings in 015 settings in 059

Automatic
mounting

pipe diamter correction

calibr.

first point corrects offset

further points correct linearity (option)

safety settings L00-FMR532xx-19-00-00-en-003

linearisation
option

(description see BA 217F)

extended calibr.

...

47
Commissioning Radar Tank Gauge

To successfully commission a precise measurement to the nearest mm, it is important

you carry out a history reset on first installation after mechanical installation and after
the basic setup of the device (see Page 56). Only after a history reset the mounting cali-
bration is carried out. Enter the measurement offset as the first point in the dip table for
the mounting calibration. When a value is dipped at a later date, make a second entry
into the dip table, again using the semi-automatic mode. This way, you can easily carry
out a linearization of the measurement.
When configuring the function in "basic setup" (00) please take into account the
following notes:
• Select the functions as described on page 31.
• Some functions can only be used depending on the parameterization of the
instrument. For example, the pipe diameter of a stilling well can only be entered if
"stilling well" was selected beforehand in the "tank shape" (002) function.
• Certain functions (e.g. starting an interference echo mapping (053)) prompt you to
confirm your data entries. Press O or S to select "YES" and press F to confirm. The
function is now started.
• If you do not press a key during a configurable time period (→ function group
"display (09)"), an automatic return is made to the home position (measured value
display).

Note!
• The instrument continues to measure while data entry is in progress, i.e. the current
measured values are output via the signal outputs in the normal way.
• If the envelope curve mode is active on the display, the measured values are updated
in a slower cycle time. Thus, it is advisable to leave the envelope curve mode after the
measuring point has been optimized.
• If the power supply fails, all preset and parameterized values remain safely stored in
the EEPROM.

Note!
All functions are described in detail, as is the overview of the operating menu itself, in
the 7500 RTG "Service manual and description of instrument functions".

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6.4 Basic Setup with the VU 331

Function "measured value" (000)

– + E
⇒
This function displays the current measured value in the selected unit
(see "customer unit" (042) function). The number of digits after decimal point can be
selected in the "no.of decimals" (095) function. The length of the bargraph corresponds
to the percentile value of the present measured value with regard to the span.

6.4.1 Function group "basic setup" (00)

– + E
⇒
Function "tank shape" (002)

– + E
⇒
This function is used to select the tank shape.

Note!
For the application of the 7532 RTG the selection "stilling well" has to be chosen in the
function "tank shape" (002).

Selection:
• dome ceiling
• horizontal cyl
• bypass
• stilling well
• flat ceiling (Typical ceiling of storage tanks: a slight slope of only a few degrees can
be neglected.)
• sphere

L00-FMR2xxxx-14-00-00-en-007

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Commissioning Radar Tank Gauge

Function "medium property" (003)

– + E
⇒
This function is used to select the dielectric constant.

Selection:
• unknown
• < 1.9
• 1.9 ... 4
• 4 ... 10
• > 10

Product class DK (er) Examples

A 1,4 … 1,9 non-conducting liquids, e.g. liquefied gas 3)

B 1,9 … 4 non-conducting liquids, e.g. benzene, oil, toluene, …

C 4 … 10 e.g. concentrated acids, organic solvents, esters, aniline,

alcohol, acetone, …

D > 10 conducting liquids, e.g. aqueous solutions, dilute acids and

alkalis

3)Treat Ammonia NH3 as a medium of group A, i.e. always use a stilling well.

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Function "process cond." (004)

– + E
⇒
This function is used to select the process conditions.

Selection:
• standard
• calm surface
• turb. surface
• agitator
• fast change
• test:no filter

standard calm surface

For all applications that do Storage tanks with immersion

not fit into any of the tube or bottom filling
following groups.

The filter and output The averaging filters and

damping are set to average output damping are set to
values. high values.
-> steady meas. value
-> precise measurement
-> slower reaction time

Note!
The phase evaluation of the 7500 RTG (see »Function "auto-correction" (031)« on
page 57) is only activated if you select the measuring conditions "standard" or
"calm surface". We strongly recommend that, in the case of rough product surfaces or
rapid filling, you activate the appropriate application parameters.

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Commissioning Radar Tank Gauge

Function "empty calibr." (005)

– + E
⇒
This function is used to enter the distance from the flange (reference point of the
measurement) to the minimum level (=zero).

L00-FMR2xxxx-14-00-06-en-008
Caution!
For dish bottoms or conical outlets, the zero point should be no lower than the point at
which the radar beam hits the bottom of the tank.

Function "full calibr." (006)

– + E
⇒
This function is used to enter the distance from the minimum level to the maximum level
(=span).

L00-FMR2xxxx-14-00-06-en-009

In principle, it is possible to measure up to the tip of the antenna. However, due to

considerations regarding corrosion and build-up, the end of the measuring range
should not be chosen any closer than 50 mm (2”) to the tip of the antenna.

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Note!
If bypass or stilling well was selected in the "tank shape" (002) function, the pipe
diameter is requested in the following step.

Function "pipe diameter" (007)

– + E
⇒
This function is used to enter the pipe diameter of the stilling well or bypass pipe.

100% 100%

L00-FMR532xx-14-00-00-xx-001
0%

0%

ø ø d2

Microwaves propagate slower in pipes than in free space. This effect depends on the
inside diameter of the pipe and is automatically taken into account by the 7500 RTG. It
is only necessary to enter the pipe diameter for applications in a bypass or stilling well.
If mounting the 7532 RTG on stilling wells with a widening of the pipe, the inner diam-
eter of the lower part of the pipe (d2 in the Fig.) must be entered. This is the part of the
stilling well, where the measurement is actually performed.

Function "dist./ meas. value (008)"

– + E
⇒
The distance measured from the reference point to the product surface and the level
calculated with the aid of the empty adjustment are displayed. Check whether the values
correspond to the actual level or the actual distance. The following cases can occur:
• Distance correct – level correct -> continue with the next function, "check
distance" (051)
• Distance correct – level incorrect -> Check "empty calibr." (005)
• Distance incorrect – level incorrect -> continue with the next function, "check
distance" (051)

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Commissioning Radar Tank Gauge

Function "check distance" (051)

– + E
⇒
This function triggers the mapping of interference echoes. To do so, the measured
distance must be compared with the actual distance to the product surface. The
following options are available for selection:
Selection:
• distance = ok
• dist. too small
• dist. too big
• dist. unknown
• manual

L00-FMR2xxxx-14-00-06-en-010
distance = ok
• mapping is carried out up to the currently measured echo
• The range to be suppressed is suggested in the "range of mapping (052)" function
Anyway, it is wise to carry out a mapping even in this case.

dist. too small

• At the moment, an interference is being evaluated
• Therefore, a mapping is carried out including the presently measured echoes
• The range to be suppressed is suggested in the "range of mapping (052)" function

dist. too big

• This error cannot be remedied by interference echo mapping
• Check the application parameters (002), (003), (004) and "empty calibr." (005)

dist. unknown
If the actual distance is not known, no mapping can be carried out.

manual
A mapping is also possible by manual entry of the range to be suppressed. This entry is
made in the "range of mapping (052)" function.

Caution!
The range of mapping must end 0.5 m (20") before the echo of the actual level. For an
empty tank, do not enter E, but E – 0.5 m (20").

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Function "range of mapping" (052)

– + E
⇒
This function displays the suggested range of mapping. The reference point is always
the reference point of the measurement (see page 46). This value can be edited by the
operator.
For manual mapping, the default value is: 0 m.

Function "start mapping" (053)

– + E
⇒
This function is used to start the interference echo mapping up to the distance given in
"range of mapping" (052).

Selection:
• off: no mapping is carried out
• on: mapping is started

55
Commissioning Radar Tank Gauge

Display "dist./meas.value (008)"

– + E
⇒
The distance measured from the reference point to the product surface and the level
calculated with the aid of the empty alignment are displayed again. Check whether the
values correspond to the actual level or the actual distance. The following cases can
occur:
• Distance correct – level correct -> basic setup completed
• Distance incorrect – level incorrect -> a further interference echo mapping must be
carried out "check distance" (051).
• Distance correct – level incorrect -> check "empty calibr." (005)

Function "history reset" (009)

– + E
⇒
By this function a history reset of the device is performed, i.e. the correspondence table
between level an index values is deleted. A new correspondence table will be filled and
stored after the history reset, see page 57.

Caution!
Perform only after first installation (see »Function "auto-correction" (031)« on page 57).
In this case also effect a reset of the dip table in function "dip table mode" (033).

– + E
⇒
⇓ After 3 s, the following message appears

Note!
After basic calibration, it is wise to evaluate the measurement using the envelope curve
(function group "display" (09)).

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6.5 Mounting calibration with VU 331

6.5.1 Function group "mounting calibr." (03)

– + E
⇒
Function "tank gauging" (030)

– +
⇒
E

Using this function, you can either enter a dip table or carry out an auto-correction.

Function "auto-correction" (031)

– + E
⇒
When measuring levels with radar systems, so-called "multipath reflections" can affect
the level signal giving rise to serious measuring errors. "Multipath reflections" also
include radar beams which are received by the radar system, which have not been
reflected directly by the medium surface. They may reach the antenna via the basin wall
and the medium surface. This phenomenon is particularly noticeable with devices
mounted near to walls, as soon as the conical radar beam strikes the basin wall.
The 7500 RTG can automatically discover and correct measuring errors due to this
"multiple path" propagation. This is because it uses two independent sets of information
when evaluating reflection signals:
• Firstly, it evaluates the amplitude of the reflected energy using the so-called envelope
curve system.
• Secondly, it evaluates the phase of the reflected energy.

The decisive factor for a constant output signal is to assign the phase values to the
associated level values. This assignment is ensured using a correspondence table (index
correction table). The 7500 RTG learns this for the specific application after installation
(learning period).
Therefore, after mounting the device, and after completing the basic calibration, a
history reset must be performed (enter "yes" in the "history reset" (009) function in the
"basic setup " (00) function group).
Do not switch off the radar system during filling and emptying operations during the
teach-in phase. Switching off when there are only negligible level changes produces no
error.

" Caution!
During the learning period, fast filling/emptying or turbulent surfaces can result in
switching off and on the phase evaluation. Subsequently observed measurement errors
will disappear as soon as tank levels come back to areas measured by 7500 RTG
previously with activated phase evaluation. If the observed measurement errors are
curetted by dip table entries, the 7500 RTG will take care of these corrections and
automatically adjust the index correction table. Do NOT correct any settings in the basic
calibration or the extended calibration.

Note!
Immediately after installation, the 7500 RTG measures with the specified mm-accuracy.
Until the level range has been completely covered by the medium (setting up the

57
Commissioning Radar Tank Gauge

correction table), the maximum permissible filling speed is 100 mm level

change / min. After this, the fill speed has no limitation.

Function "pipe diam. corr." (032)

– + E
⇒
For level measurement in stilling wells, radar systems require highly precise pipe inner
diameter data. An mm-exact level measurement cannot be guaranteed for deviations
from the actual stilling well inner diameter of more than ± 0.1mm to the value entered
in the function group "basic setup" (00). The errors which occur as a result are linear and
can be corrected with a dip table containing at least two entries.
The 7500 RTG also has an automatic pipe inner diameter correction. This adjusts the
entered stilling well inner diameter (input in the function group
"basic setup" (00)) to the actual values. However, this presupposes that the value entered
in the function group "basic setup" (00) matches the actual pipe inner diameter
accurately as possible. The user-defined value entered in the function group
"basic setup" (00) can be corrected with this value. In order to do this, switch on the "pipe
diam. corr." (032) function, after a level change of at least 5 m has occurred since start-
up. The pipe diameter, which the instrument determines automatically, will then be
transmitted to the "pipe diameter" (007) function.

Note!
Only if the "pipe diameter" (007) function has changed its value, it is necessary to per-
form a "history reset" (009) and to delete the dip table after activation of the "pipe diam.
corr." (032) function. Otherwise the level change of 5 m has not yet been exceeded. The
"pipe diam. corr." (032) function must be deactivated again and the procedure should be
repeated at a later point of time.

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Display "custody mode" (0A9)

– + E
⇒
This indicates the instrument calibration mode. The calibration mode (active) can be set
using the hardware security lock on the electronics (see Page 34).

Selection:
• inactive
• active pos.
• active neg.

active pos.
The custody mode (instrument is lead-sealed and accurate to the nearest mm) is active
and is held.

active neg.
Custody mode (instrument is lead-sealed and accurate to the nearest mm) is activated
and not held, e.g. because the signal-to-noise ratio is less than 10 dB (refer to
function "echo quality" (056) in the function group "extended calibr." (05)).

Caution!
After entering all the values and completing mounting and aligning work, enter the
Reset Code "555" in the function "history reset" (009) of the "basic setup" (00) function
group to reset the instrument history for auto-correction.

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Commissioning Radar Tank Gauge

Dip table
The dip table is used to correct the level readings of the 7500 RTG using independently
taken hand dips. The dip table is used in particular to adapt the level gauge to the
specific application conditions as mechanical offset and tank/stilling well design.
Depending on national regulations, national inspectors will dip the tank at one to three
levels during a calibration run and check the level readings.
Only one value pair must be entered into the dip table to correct the measurement
offset.
If a second value pair is entered into the dip table, the 7500 RTG accepts the corrected
measured values identically for both value pairs. All other measured values are
determined by linear extrapolation.
If you enter more than two value pairs, the system carries out a linear interpolation
between adjacent value pairs. Outside these value pairs, extrapolation is also linear.

basic setup

history reset

dip table
alternatives
preferred choice:
hand dip and collect hand dip and
immediate measurement data over
offset correction in full measurement range
semi-automatic mode

L00-FMR53xxx-19-00-00-en-014
collect further hand dip data;
if deviation from measurements evaluate collected data;
> 4 mm and level change > 2 m: enter characteristic value
enter a new dip value pairs into the dip table
into dip table using the using the manual mode
semi-automatic mode

Figure 8: Alternative procedures to fill the dip table.

To collect and enter data into the dip table, two alternative procedures may be carried
out. In order not to mix up measurement values corrected by the offset or linearization
of the dip table with uncorrected measurement values, it is recommended to use the
semi-automatic mode of the dip table to enter new data pairs. In this case, the first dip
value should be entered immediately after the basic calibration. Further linearization
points should be entered only after a level change of at least 2 m (see Figure 8:,
preferred choice) and a deviation between the "uncorrected measurement value" and the
hand dip value of at least 4mm.
If this procedure can not be followed, then NO value pair should be entered into the dip
table after basic calibration. Measurement data and hand dip values should be collected
over the full measurement range and be evaluated with regard to a good linear fit. Only
then characteristic value pairs should be entered into the dip table using the "manual
mode" (see Figure 8:, right side). If further linearization is needed, further hand dip
values should be entered using only the "semi-automatic mode".

Note!
The offset should NOT be determined and entered within the close range of the antenna
(conf. definition of the safety distance) or immediately in the range of the tank bottom,
because within these ranges interferences of the radar signal may occur.

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7532 Commissioning

Note!
The dip table can be printed out using the ToF-Tool. Before doing this, the ToF Tool
must be reconnected to the instrument in order to update the values within the ToF Tool.

Note!
Make your inputs into the dip table in semi-automatic mode. We advise you to leave
"auto correction" (031) activated ("on") while you enter your inputs.

Caution!
After entering one or more points into the dip table, make sure that the dip table is
activated and left in the "table on" dip table mode.

Function "dip table state" (037)

– + E
⇒
This function displays the dip table status.

Display:
• table on
• table off

table on
Indicates whether the dip table is active.

table off
Indicates whether the dip table is not active.

Function "dip table mode" (033)

– + E
⇒
The dip table can be switched on or off using this function.

Selection:
• manual
• semi-automatic
• table on
• table off
• clear table
• view

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Commissioning Radar Tank Gauge

manual
The value pairs in the dip table can be read and written. You can enter the measured
value and the dip value.
–uncorrected measured value:
This is the measured value supplied by the instrument, NOT corrected by the dip
table. The choice of measured value, level or remaining fill height is dependent on
the instrument setting.
–Dip value:
This is the level or distance to flange respectively, given by the hand dip. This value
should be used to correct the measured value.
The "manual mode" of the dip table can be used to enter collected data after a series
of data pairs taken at different tank levels.

Note!
The bigger the distance between the different levels while taking hand dips, the more
accurate the linearization of the dip table will be.

semi-automatic
The value pairs in the dip table can be read. You can enter the dip value only. When there
are new value pairs, the current level or distance is accepted as the measured value.

table on
The dip table is switched on.

table off
The dip table is switched off.

clear table
The complete dip table is deleted. The table is switched off. The number of free table
entries is set to the maximum value (= 32).

View
The value pairs in the dip table can only be read. You can still select this menu option,
even if there is no dip table available. In this case, the number of free table entries is at
maximum value (= 32).

Function "dip table" (034)

– + E
⇒
This function edits measured variable. The number behind the entry "remain" indicates
the current number of remaining free value pairs. The maximum number of value pairs
is 32; after each entry, the remaining number is decremented.

Note!
The uncorrected measured value is displayed in the "dip table" (034) function. This may
differ considerably from the measured values when a dip table is activated.

Function "dip table" (035)

– + E
⇒
This function edits the dip value.

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Function "dip table handl." (036)

– + E
⇒
Use this function to enter the dip value (level or distance) which will correct the mea-
surement values.

Selection:
• new point
• edit point
• store point
• delete point
• return
• next point
• previous point

General procedure:
To enter a new point into the dip table, use
"new point" to enter the value (pairs),
"store point" to sort the new value (pairs),
"return" to go to the dip table mode and
"table on" to activate the dip table.

new point
You can enter a new point. A suggested value is displayed for the measured variable, the
dip value of the current level or the distance. With semi-automatic inputs, the current
level or the current remaining fill height is displayed as proposed dip value. The new
value pair can be altered without selecting the
"edit point" parameter.
If the table is full, you can still select this parameter. In this case, the number of free
table entries stands at minimum value (= 0).

edit point
The displayed value pair can be changed. Only the dip value can be changed with semi-
automatic input mode.

Caution!
To accept the value pair in the table, confirm it with "store point".

store point
The displayed value pair is sorted in the table.

Note!
For sorting, the following criteria must be met:
• Measured variables may not be equal but have different dip values.
• A measured variable available in the table is recognized as equal when it is closer than
1 mm to the sorting value.
• After successful sorting, the setting remains at "edit point" and the number of free
table entries is decremented.

Caution!
If the value cannot be sorted, the setting remains at the previous menu option. No
warning or error message is generated. However, the number of remaining table entries
is not decremented.

63
Commissioning Radar Tank Gauge

delete point
The currently displayed point is deleted from the table. After deletion, the previous point
is displayed. If the table only consisted of one point before deletion, then the current
measured variable is displayed as a value pair.

return
By selecting this point, you return to the function "dip table mode" (033).

next point
This scrolls down in the table. If the table is empty, you can still select this option.
However, the displayed value does not change.

previous point
This scrolls up in the table. If the table is empty, you can still select this option. However,
the displayed value does not change.

Caution!
After entering one or more points into the dip table, make sure that the dip table is
activated in the "table on" dip table mode.

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6.5.2 Envelope curve with VU 331

After the basic setup, an evaluation of the measurement with the aid of the envelope
curve ("display" (09) function group) is recommended.

Function "plot settings" (09A)

– + E
⇒
Here you can select which information is shown on the display:
• envelope curve
• env. curve+FAC (for FAC see 7500 RTG "Service manual and description of
instrument functions")
• env. curve+suppress. (i.e. the tank map is also displayed)

L00-FMRxxxxx-07-00-00-en-004
Function "recording curve" (09B)
This function determines whether the envelope curve is read as:
• single curve
or
• cyclic

– + E
⇒

Note!
If the envelope curve mode is active on the display, the measured values are updated in
a slower cycle time. Thus, it is advisable to leave the envelope curve mode after the
measuring point has been optimized.

65
Commissioning Radar Tank Gauge

6.6 Basic Setup with the ToF Tool

To carry out the basic setup with the ToF Tool operating program, proceed as follows:
• Start the ToF Tool operating program and establish a connection
• Select the "basic setup" function group in the navigation bar

The following display appears on the screen:

Basic Setup step 1/5:

• Status image
• Enter the measuring point description (TAG number).

Change to the next page

Note!
• Each parameter that is changed must be confirmed with the RETURN key!
• The "Next" button moves you to the next screen display:

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Basic Setup step 2/5:

• Enter the application parameters:
–tank shape (for a description, see page 49)
–medium property (for a description, see page 50)
–process cond. (for a description, see page 51)

Basic Setup step 3/5:

If "stilling well" or "bypass" is selected in the "tank shape" function, the following display
appears on the screen:
• empty calibr. (for a description, see page 52)
• full calibr. (for a description, see page 52)
• Diameter of bypass / stilling well (for a description, see page 53)

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Commissioning Radar Tank Gauge

Note!
You can also specify the pipe diameter in this display.

Basic Setup step 4/5:

• This step starts the tank mapping
• The measured distance and the current measured value are always displayed in the
header
• A description is given on page 56

measured value

distance

Step 5/5:
After the first installation of the device, initialise the index correction table (compare
page 57) by activating the history reset 555.

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6.6.1 Envelope curve with the ToF Tool

After the basic setup, an evaluation of the measurement using the envelope curve is
recommended.

6.6.2 User-specific applications (operation)

To set the parameters of user-specific applications, see the 7500 RTG "Service manual
and description of instrument functions".

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Commissioning Radar Tank Gauge

6.7 Mounting calibration with the ToF Tool

To carry out the basic setup with the ToF Tool operating program, proceed as follows:
• Start the ToF Tool operating program and establish a connection
• Select the "mounting calibr." function group in the navigation bar

The following display appears on the screen:

Mounting calibration step 1/2:

• auto correction (description see page 57)
• pipe diam. corr. (description see page 58)

change to next page

Note!
• Each parameter that is changed must be confirmed with the RETURN key!
• the "Next" button moves you to the next screen display:

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Mounting calibration step 2/2:

• dip table mode (description see page 61)
• meas. v. (description see page 62)
• dip value (see page 62)
• dip table handl. (description see page 63)
• dip table state (description see page 61)
• left dip t.entr. (description see page 61)

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Commissioning Radar Tank Gauge

72 Installation and Operations Manual

7532 Maintenance

7 Maintenance
The 7500 RTG measuring instrument requires no special maintenance.

Exterior cleaning
When cleaning the exterior of measuring devices, always use cleaning agents that do not
attack the surface of the housing and the seals.

Replacement
After a complete 7500 RTG or electronic module has been replaced, the parameters can
be downloaded into the instrument again via the communication interface. Prerequisite
to this is that the data were uploaded to the PC beforehand using the ToF Tool /
Commuwin II.
Measurement can continue without having to carry out a new setup.

• You may have to activate linearization

• You may need to record the tank map again

After an antenna component has been replaced, a new calibration must be carried out.

73
Maintenance Radar Tank Gauge

74 Installation and Operations Manual

7532 Accessories

8 Accessories
Various accessories, which can be ordered separately from Varec, are available for the
7500 RTG.

Weather protection cover

A Weather protection cover made of stainless steel is available for outdoor mounting
(order code: 543199-0001). The shipment includes the protective cover and tension
clamp.

L00-FMR53xxx-00-00-06-en-001
Commubox FXA 191 HART
For intrinsically safe communication with ToF Tool or Commuwin II via the RS 232C-
interface.

Service adapter FXA 193

For communication with ToF Tool via the display connector. (Bestell-Nr.: 50095566).

Commuwin II
Operating software for intelligent instruments.

75
Accessories Radar Tank Gauge

76 Installation and Operations Manual

7532 Troubleshooting

9 Troubleshooting

9.1 Troubleshooting instructions

77
Troubleshooting Radar Tank Gauge

7500 RTG - Troubleshooting

L00-FMR53xxx-19-00-00-en-010

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7532 Troubleshooting

9.2 System error messages

Code Description Possible cause Remedy

A102 checksum error device has been powered off reset;

general reset & new before data could be stored; avoid emc problem; if
calibr.required emc problem; E²PROM defect alarm prevails after reset,
exchange electronics

W103 initialising - please E²PROM storage not yet wait some seconds; if
wait finished warning prevails, exchange
electronics

A106 downloading please processing data download wait until warning

wait disappears

A110 checksum error device has been powered off reset;

general reset & new before data could be stored; avoid emc problem; if
calibr.required emc problem; E²PROM defect alarm prevails after reset,
exchange electronics

A111 electronics defect RAM defective reset;

if alarm prevails after
reset, exchange electronics

A113 electronics defect ROM defective reset;

if alarm prevails after
reset, exchange electronics

A114 electronics defect E2PROM defective reset;

if alarm prevails after
reset, exchange electronics

A115 electronics defect general hardware problem reset;

if alarm prevails after
reset, exchange electronics

A116 download error checksum of stored data not restart download of data
repeat download correct

A121 electronics defect no factory calibration existant; contact service

E²PROM defective

W153 initialising - please initialisation of electronics wait some seconds; if

wait warning prevails, power off
device and power on again

A155 electronics defect hardware problem reset;

if alarm prevails after
reset, exchange electronics

A160 checksum error device has been powered off reset;

general reset & new before data could be stored; avoid emc problem; if
calibr.required emc problem; E²PROM defect alarm prevails after reset,
exchange electronics

A164 electronics defect hardware problem reset;

if alarm prevails after
reset, exchange electronics

A171 electronics defect hardware problem reset;

if alarm prevails after
reset, exchange electronics

A231 sensor 1 defect HF module or electronics exchange HF module or

check connection defective electronics

Table 3: System error messages

79
Troubleshooting Radar Tank Gauge

Code Description Possible cause Remedy

A270 custody switch switch for custody transfer check position of custody
undef may be defective switch
check position exchange electronics

# inconsistency between phase check basic calibration

and amplitude evaluation check mounting calibration
inconsistent microfactor check echo quality
inconsistent index mapping reset history "555"
check stilling pipe
diameter
switch off autocorrection

A272 electronics defect inconsistency in amplification exchange electronics

amplifier

W275 electronics defect offset drift of A/D commuter exchange electronics

factory setting

W511 no factory factory calibration has been record new factory

calibration ch1 deleted calibration

A512 recording of mapping active wait some seconds until

mapping please wait alarm disappears

W601 linearization ch1 linearization not correct linearization table

curve not monotone monotonously increasing

W611 less than 2 number of entered correct linearization table

linearization points linearization points < 2
for channel 1

W621 simulation ch. 1 on simulation mode is active switch off simulation mode

E641 no usable echo echo lost due to application check installation;

channel 1 conditions of built up on optimize orientation of
check calibr. antenna antenna; clean antenna

E651 level in safety level in safety distance alarm will disappear as

distance - risk of soon as level leaves safety
overspill distance;

A671 linearization ch1 not linearization table is in edit activate linearization table
complete, not mode
usable

W681 current ch1 out of current out of range (3,8 mA check calibration and
range ... 21,5 mA) linearization

Table 3: System error messages

80 Installation and Operations Manual

7532 Troubleshooting

9.3 Application errors

Error Output Possible cause Remedy

A warning or Depending on the configuration See table of 1. See table of error messages
alarm has error messages (see page 79)
occurred. (see page 79)

Measured Measured distance yes → 1. Check empty calibr. (005) and

value (00) is (008) OK? full calibr. (006).
incorrect
F m/ft 20 mA/100% 2. Check linearization:
D m/ft (008)

→ level/ullage (040)
→ max. scale (046)
expected
→ diameter vessel (047)
→ Check table

actual no ↓
E m/ft
4 mA/0% t→
Measurement in yes → 1. Is bypass or stilling well
bypass or stilling selected
well? in tank shape (002)?

2. Is the pipe diameter

(007) correct?

no ↓

Is an yes → 1. offset (057)

FAR 10 antenna correctly set?
extension
being used?

no ↓

An interference yes → 1. Carry out tank mapping

echo → basic setup
may have been
evaluated.

No change off Interference echo 1. Carry out tank mapping

measured from → basic setup
value on installations,
20 mA/100%
nozzle 2. If necessary, clean antenna
filling/empty-
or extension on
ing 3. If necessary, select better
the
mounting position
actual antenna

expected

4 mA/0% t→

81
Troubleshooting Radar Tank Gauge

Error Output Possible cause Remedy

If the surface Signal is weakened 1. Carry out tank mapping

is not calm by the rough → basic setup
(e.g. filling, surface — the
20 mA/100%
interference 2. Set the process cond. (004) to
emptying, agi- actual "turb. surface" or
echoes
tator run- "agitator"
are sometimes
ning), the stronger
measured expected 3. Increase the output damping
value (058)
jumps sporad-
4. Optimize the orientation
ically to a
higher 4 mA/0% t→
5. If necessary, select a better
level mounting position
and/or larger antenna

20 mA/100%

actual

expected

4 mA/0% t→

During filling/ Multiple echoes yes → 1. Check the tank shape (002),
emptying e.g. "dome ceiling" or
the measured "horizontal cyl"
20 mA/100%
value jumps 2. In the range of the blocking dist.
downwards actual
(059) there is no echo evalua-
tion
→ Adapt the value
expected
3. If possible, do not select
central installation position
4 mA/0% t→
4. Perhaps use a stilling well

E 641 (loss of Level echo is too yes → 1. Check application parameters

echo) weak. (002), (003) and (004)
Possible causes:
20 mA/100% • Rough surface 2. Optimize alignment
due to filling/
3. If necessary, select a better
actual emptying
installation position and/or
• Agitator running
• Foam larger antenna
E 641
expected

4 mA/0% t→

E 641 (loss of If the instrument is configured to Hold noise level during Repeat once more empty calibr.
echo) after by loss of echo the output is set to any the initialisation (005).
turn on the value/current. phase to high. Caution!
power supply Before conformation change with
O or S to the edit mode.

82 Installation and Operations Manual

7532 Troubleshooting

9.4 Spare parts

Note!
You can order spare parts directly from your Varec service organization by giving the
order code and the serial number which is printed on the measuring transducer
nameplate (see page 7). The corresponding spare part number also appears on each
spare part. Installation instructions are given on the instruction card that is also
delivered.

Note!
If the calibration seal is broken, the national calibration authority should normally be
informed within 24 hours.

83
Troubleshooting Radar Tank Gauge

7532 RTG

The customer may exchange

modular assemblies in
accordance with Varec
instructions!

L00-FMR532xx-00-00-06-en-001

84 Installation and Operations Manual

7532 Troubleshooting

Spare parts 7532 RTG Process connection without antenna

Planar antenna
7532 RTG-

detailed order structure and variants

see spare parts price list

O-ring 49,21 x 3,53 EPDM

(Seal set 52005628)

O-ring 49,21 x 3,53 EPDM

(Seal set 52005628)

O-ring
85,32 x 3,53 FKM (green)
85,32 x 3,53 HNBR12-70
(black)
O-ring
85,32 x 3,53 FKM (green)
85,32 x 3,53 HNBR12-70
(black)

L00-FMR532xx-00-00-06-en-004
Antenna size Seal

5200 6193 DN 150 ( 6") HNBR

5200 6332 DN 150 ( 6") FKM
5200 6194 DN 200 ( 8") HNBR
5200 6333 DN 200 ( 8") FKM
5200 6195 DN 250 (10") HNBR
5200 6334 DN 250 (10") FKM

Modification nameplate
When ordering parts that are listed in the product structure (see page 8) , a check must
be made as to whether the instrument description on the nameplate is still valid, e.g. for:
• an antenna component,
• an electronics module,
• an RF module,
• a VU 331 operating and display module,
• a housing cover with window.

85
Troubleshooting Radar Tank Gauge

Housing T12
The complete order code must be specified when ordering the replacement housing so
that the correct nameplate can be delivered, e.g.

• 7532 RTG-AACWJAC1AA

You must label the nameplate yourself.

Caution!
• It is not possible to convert a standard instrument into an Ex instrument by simply
exchanging parts.
• When repairing certified instruments, the relevant regulations must be followed.
• For FM approved instruments, it is forbidden to make any changes to the instrument
that are not expressly authorized in the operating manual. Contravening this
prohibition can invalidate the approval for operation of the instrument.

9.5 Return
If you need to send a 7500 RTG back to Varec for repair, please send a completed copy
of the form printed on the last page.

• An exact description of the application.

• The chemical and physical characteristics of the product.
• A short description of the error that occurred.
• If necessary, give the error code.

Please carry out the measures described in section 1.4, “Return” on page 5 before
sending a 7500 RTG back for repair.

9.6 Disposal
In case of disposal please separate the different components according to their material
consistence.

9.7 Software history

Software version Software changes Documentation changes

/ Date

V 1.00.00 / Original software.

12.2000 Operated via:
– ToF Tool
– Commuwin II (from version
2.05.03)
– HART communicator DXR 375
with Rev. 1, DD 1.

V 01.02.00 / simplified commissioning

03.2002 history reset in basic calibration.
Operated via:
– ToF Tool (V3.0)
– Commuwin II (from version
2.05.03)
– HART communicator DXR 375
with Rev. 1, DD 1.

86 Installation and Operations Manual

7532 Technical data

10 Technical data

10.1 Technical data at a glance

Application

Application The 7500 RTG is used for highly accurate level measurement in
storage tanks and can be applied in custody transfer applications. It
meets the relevant requirements according to OIML R85 and API 3.1B.
• The 7532 RTG with planar antenna is specifically and only suited for
stilling well applications with ranges up to 38 m (124 ft).

Function and system design

Measuring principle The 7500 RTG is a "downward-looking" measuring system, operating

based on the time-of-flight method. It measures the distance from
the reference point (process connection) to the product surface. Radar
impulses are emitted by an antenna, reflected off the product surface
and received again by the radar system.

Equipment architecture The 7500 RTG can be used for measurement in a stilling well as well
as in free space. The different instrument versions are applied as
follows:
• The 7532 RTG with planar antenna is the preferred device in stilling
wells ≥ 150 mm.
• The instruments are equipped with a passive 4…20 mA output with
HART protocol.

Input

Measured variable The measured variable is the distance between a reference point
(mounting flange) and a reflective surface (e.g. medium surface). The
measured value and all parameters are displayed using either metrical
SI-units or US/UK-units (inch, ft, …).
The level is calculated based on the tank height entered.
The level can be converted into other units (volume, mass) by means
of a linearization.
In order to compensate for non-linear effects like movement of the
tank roof, an additional correction table (diptable) can be entered.

Measuring range See page 15

Output

Output signal 4…20 mA with HART protocol:

this version can be operated via the PC operating software ToF Tool
and Commuwin II. The instrument supports both point-to-point and
multidrop operation.

Signal on alarm Error information can be accessed via the following interfaces:
• Local display:
– Error symbol (see page 35)
– Plain text display
– LED’s: red LED continuously on = alarm, red LED flashes = warn-
ing
• Current output
• Digital interface

Galvanic isolation 500 V towards ground.

500 V between power supply and signal

87
Technical data Radar Tank Gauge

Auxiliary energy

Electrical connection Housing T 12 with separate terminal compartment.

Load HART Minimum load for HART communication: 250 Ω

Cable entry Cable gland: M20x1.5 or Pg13.5

Cable entry: G ½ or ½ NPT

Supply voltage See page 28

Power consumption Max. 330 mW at 16 V, max. 500 mW at 24 V, max. 600 mW at 30 V.

Current consumption Max. 21 mA (50 mA inrush current).

Power supply For stand alone operation recommended via e.g. Varec RN 221N/Z.

Performance characteristics

Reference operating According to OIML R85:

conditions • Temperature = –25…+55 °C (-13…+131 °F)
• Atmospheric pressure
• Relative humidity (air) = 65 % ±15%
• Medium properties: e.g. medium with good reflectivity and calm
surface.
• Tank diameter: signal beam hits the tank wall only at one side.
Note!
No major interference reflections inside the signal beam.

Maximum measured Absolute accuracy: 0.5 mm (2σ value)

error Inventory Control Versios: ±3 mm

Proof of accuracy for The accuracy of each 7500 RTG is established through a calibration
custody transfer ver- certificate that records the absolute and relative error at 10
sions equidistant points during the final test. For stilling well measurements
with 7532 RTG, a NMI / PTB calibrated tape with an absolute accuracy
of 0.25 mm is used.
Each 7500 RTG is delivered with the PTB and NMi type approval.
Additional initial factory verifications for custody applications are
available on demand for all 7500 RTG.

Maximum fill speed By the first pass trough of measuring range: 100 mm/min., after it
unlimited.

Non-repeatability 0,3 mm (1/64")

Hysteresis 0.3 mm

Resolution digital: 0.1 mm

analogue: 0.03 % of measuring range

Settling time Typical 15 sec

Long-term drift The long-term drift is within the specified accuracy.

Influence of ambient Within the specified accuracy according to OIML R85.

temperature

Software reliability The software used in the 7500 RTG fulfills the requirements of OIML
R85. This particularly includes:
• cyclical test of data consistency
• non-volatile memory
• segmented data storage
The 7500 RTG continuously monitor the compliance with accuracy
requirements for custody transfer measurements according to OIML
R85. If the accuracy cannot be maintained, a specific alarm is
generated on the local display and via the digital communication.

88 Installation and Operations Manual

7532 Technical data

Inventory Control Ver- All device types can be delivered as "Inventory Control Versions" with a
sions reduced accuracy of ± 3mm (under reference conditions).
To these versions, the calibration certificate or custody transfer type
approval is NOT attached.
The "Inventory Control Versions" can be selected by choosing the
option »R« in feature »70« in the order code section »Custody transfer
approvals« on page 8.

Operating conditions

Operating conditions

Engineering tips See page 14

Environment

Ambient temperature Ambient temperature for the transmitter:

range • Standard: -40 °C … +80 °C (-40 °F … +176 °F)
• For calibration to regulatory standards: -25 °C ... +60 °C (-30
°F…+140 °F)
With Tu<-20 °C and Tu>+60 °C the operability of the LC-display is
reduced.
A weather protection cover should be used for outdoor operation if
the instrument is exposed to direct sunlight.

Storage temperature -40 °C ... +80 °C (-40 °F … +176°F)

Climate class DIN EN 60068-2-38 (test Z/AD)

Degree of protection • housing: IP 65, NEMA 4X (open housing: IP20, NEMA 1)

• antenna: IP 68 (NEMA 6P)

Vibration resistance DIN EN 60068-2-64 / IEC 68-2-64: 20…2000 Hz, 5 (m/s²)²/Hz

Cleaning of the antenna See »Technical Information« TEC028

Electromagnetic com- • emissions according to EN 61326; equipment class B

patibility • compatibility according to EN 61326; appendix A (industrial area,
10 V/m) and Namur recommendation EMC (NE 21).

Process conditions

Process temperature See »Technical Information« TEC028

range

Process temperature See »Technical Information« TEC028

limits

Process pressure limits See »Technical Information« TEC028

Dielectric constant • in a stilling well: εr ≥ 1.4

• in free space: εr ≥ 1.9

Wetted parts • Planar, gas-tight

Wetted parts: 1.4435 / HNBR (Hydrated Nitrit Butadien Rubber,
resistent to NH3) or FKM / PTFE glas fiber laminat
Note!
The planar antenna is not resistant to hot vapor!
• Horn adapter for increase of diameter
Wetted parts: 1.4435

89
Technical data Radar Tank Gauge

Mechanical construction

Design, dimensions See page 13

Weight Approx 6 kg + weight of flange

Material See page 8

Process connection see page 8

All process connections dispose of a gas-tight glass feed-through to
prevent any gas leakage to the inside of the housing.

Human interface

Operation concept See page 31

Display See page 31

Certificates and approvals

CE approval The measuring system meets the legal requirements of the EC-
guidelines. Varec confirms the instrument passing the required tests
by attaching the CE-mark.

RF approvals R&TTE 1999/5/EG, FCC CRF 47, part 15

Overspill protection PTB , NMi and many other national approvals

External standards and EN 60529

guidelines Protection c3lass of housing (IP-code)
EN 61010
Safety regulations for electrical devices for measurement, control,
regulation and laboratory use.
EN 61326
Emissions (equipment class B), compatibility (appendix A – industrial
area)
NAMUR
Standards committee for measurement and control in the chemical
industry
API (American Petroleum Institute)
Particularly "Manual of Petroleum Measurement Standards".
OIML R85 (Organisation Internationale de Metrologie Legale)

Ex approval XA 081F-A
Installation 7500 RTG (T12 / EEx ia IIC T6…T1)
PTB 00 ATEX 2067 X, Equipment marking: (II 1/2 G)

Ordering Information

The Varec service organisation can provide detailed ordering

information an information on the order codes on request.

Accessories

see page 75

Supplementary Documentation

Supplementary • System Information

Documentation • Technical Information
• Operating Instructions

90 Installation and Operations Manual

7532 Appendix

11 Appendix

11.1 Operating menu HART (Display modul), ToF Tool

91
Appendix Radar Tank Gauge

basic setup 00 tank shape 002 medium property 003 process cond. 004 empty calibr. 005 full calibr. 006
dome ceiling unknown standard enter value enter value
horizontal cyl. DK: < 1.9 calm surface
bypass DK: 1.9 … 4 turb. surface
stilling well DK: 4 … 10 add. agitator
flat ceiling DK: > 10 fast change pipe diameter 007
sphere test: no filter enter value

safety settings 01 output on alarm 010 outp. echo loss 012 delay time 014
MIN -10% 3.6mA alarm in case of echo loss
MAX 110% 22mA hold max. 4000 sec.
hold default: 30 s
user specific output on alarm 011 ramp %MB/min ramp %/min 013
enter value enter value

mounting calibr. 03 tank gauging 030 dip table mode 033

dip table view dip table state 037 dip table 034 dip table handl. 036
manual
meas.v. 034 next point
semi-automatic
dip value 035 previous point
table on new point
table off dip table state 037
edit point
clear table store point
delete point
auto correct.
return

linearisation 04 level/ullage 040 linearisation 041

level CU 040 manual 041 customer unit 042 linearisation next point 045
ullage CU semi-automatic table no. 043 yes
table on input level 044
input volume 045 no
horizontal cyl customer unit 042
linear customer unit 042
reset table
level DU 040
ullage DU

extended calibr. 05 selection 050 dist./meas value 008 check distance 051 range of mapping 052 start mapping 053
mapping D and L distance = ok input of off
are displayed dist. too small mapping range on
manual
dist. unknown
dist. too big
common

extended map..
pres. Map dist 054 cust. Tank map 055
is displayed inactive
active
reset

output 06 commun. address 060 no. of preambels 061 low output limit 062 fixed current 063
off off
on on fixed cur. value 064

display 09 language 092 back to home 093 format display 094 no. of decimals 095
enter time decimal x
default: 100 s 1/16” x.x
x.xx
x.xxx

diagnostics 0A present error 0A0 previous error 0A1 clear last error 0A2 reset 0A3 unlock parameter 0A4
for reset code for reset code
see manual see manual

system parameter 0C tag no. 0C0 protocol+sw-no. 0C2 software no. 0C3 serial no. 0C4
custody transfer

Note! The default values of the parameters are typed in boldface.

92 Installation and Operations Manual

 7532 Appendix

dist./meas.value 008 check distance 051 range of mapping 052 start mapping 053 history reset 009
distance = ok input of off no
dist. too small mapping range on yes
D and L
dist. too big
are displayed
manual

dist. unknown

safety distance 015 in safety dist. 016 ackn. alarm 017 overspill protection 018
from blocking alarm no standard
distance warning yes german WHG
default: 0.1m self holding

auto correction 031 pipe diam. corr. 032

off off
on on

Return to Group Selection

max. scale 046 diameter vessel 047
max. scale 046

dist./meas.value 008
D and L
are displayed

echo quality 056 offset 057 output damping 058 blocking dist. 059
is displayed will be added to the enter value is displayed
measured level default: 5 s

simulation 065 output current 067

sim. off
sim. level simulation value 066
sim. volume
sim. current

sep. character 096 display test 097 plot settings 09A recording curve 09B
. point off envelope curve single curve
, comma on env.curve+FAC cyclic
env.curve+cust.map

measured dist. 0A5 measured level 0A6 application par. 0A8 custody mode 0A9
not modified inaktiv
modified aktiv positiv
aktiv negativ

distance unit 0C5 download mode 0C8

93
Appendix Radar Tank Gauge

11.2 Operating matrix HART / Commuwin II

94 Installation and Operations Manual

 7532

Operating Matrix HART / COMMUWIN II

Function group V-CWII H0 H1 H2 H3 H4 H5 H6 H7 H8 H9

00 basic setup V0 measured value tank shape medium property process cond. empty calibr. full calibr. pipe diameter

01 safety settings V1 output on alarm output on alarm outp. echo loss ramp %span/min delay time safety distance in safety dist. ackn. alarm overspill protection

03 mounting calibr. V2 tank gauging auto correction pipe diam. corr. dip table mode dip table dip table dip table handl. dip table state

04 linearisation V3 level/ullage linearisation customer unit table no. input level input volume max. scale diameter vessel

05 extended calibr. V4 check distance range of mapping start mapping pres. Map dist cust. Tank map echo quality offset output damping blocking dist.

06 output V5 commun. Address no. Of preambels low output limit fixed current fixed current simulation simulation value output current

09 display V6 language back to home format display no. of decimals sep. character

0D service V7

0A diagnostics V9 present error previous error clear last error reset unlock parameter measured dist. measured level application par. custody mode

0C system parameter VA tag no. protocol+sw-no. software no. serial no. distance unit download mode
Appendix

95
Appendix Radar Tank Gauge

11.3 Description of functions

Note!
A detailed description of the function groups, functions and parameters is given in the
the 7500 RTG "Service manual and description of instrument functions".

96 Installation and Operations Manual

7532 Appendix

11.4 Function and system design

11.4.1 Measuring principle

The 7500 RTG is a "downward-looking" measuring system, operating based on the
time-of-flight method. It measures the distance from the reference point (process
connection) to the product surface. Radar impulses are emitted by an antenna, reflected
off the product surface and received again by the radar system.

L00-FMR53xxx-15-00-00-en-001
Input
The reflected radar impulses are received by the antenna and transmitted into the
electronics. A microprocessor evaluates the signal and identifies the level echo caused
by the reflection of the radar impulse at the product surface. The unambiguous signal
identification is accomplished by the PulseMaster® software based on many years of
experience with time-of-flight technology. The mm-accuracy of the 7500 RTG is
achieved with the patented algorithms of the PhaseMaster® software.
The distance D to the product surface is proportional to the travel time t of the impulse:

D = c · t/2,
with c being the speed of light.

Based on the known empty distance E, the level L is calculated:

L=E–D

Reference point for "E" is the lower surface of the process connection.
The 7500 RTG is equipped with functions to suppress interference echoes. The user can
activate these functions. They ensure that interference echoes (e.g. from edges and weld
seams) are not interpreted as level echo.

97
Appendix Radar Tank Gauge

Output
The 7500 RTG is commissioned by entering an empty distance E (=zero), a full distance
F (=span), and an application parameter. The application parameter automatically
adapts the instrument to the measuring conditions. The data points “E” and “F”
correspond with 4mA and 20mA for instruments with current output. They correspond
with 0 % and 100% for digital outputs and the display module.
A linearization with max. 32 points, based on a table entered either manually or semi-
automatically, can be activated locally or remotely. This function provides a
measurement in engineering units and a linear output signal for spheres, horizontal
cylindrical tanks, and vessels with conical outlet.

11.4.2 Equipment architecture

Stand-alone
The 7500 RTG can be used for measurement in a stilling well as well as in free space.
The different instrument versions are applied as follows:
• The 7532 RTG with planar antenna is the preferred device in stilling wells ≥ 150 mm.
• The 7530 RTG with horn antenna can be used in stilling wells with a diameter
<150 mm. However, for these diameters no custody transfer approval is available.
• The 7533 RTG with parabolic antenna is preferred for free-space measurements. The
7530 RTG with horn antenna can be used as an alternative for small nozzle diameters.
• The 7531 RTG with rod antenna (PTFE) should be used for measurements of highly
aggressive media (e.g. sulphur).
• The instruments are equipped with a passive 4…20 mA output with HART protocol.

The complete measuring system consists of:

SPS

- COMMUWIN II - ToF Tool

- ToF Tool

Service-Adapter
Commubox
FXA 193
FXA 191
HART

HART

2x Messumformer- L00-FMR53xxx-14-00-06-en-002
Anzeige- und ENDRESS + HAUSER

speisegerät Bedienmodul %

RN 221 N VU 331
– + E

dsdmdm
df das.
asdas fa
asas la.

DELTABAR: * * * * * * * *
ONLINE
1 QUICK SETUP
2 OPERATING MENU
3 PV 352 mbar
4 SV 0 °C

HELP SAVE

6
9 Page
Up

Bksp Delete

Page
On

#%& ABC DEF

1 2 3
Copy Paste Hot Key

GHI JKL MNO

4 5 6
Insert + Hot Key

PQRS TUV W XY Z
7 8 9
,()‘
.
_<>
0
+*/
-
HART-Handbediengerät
FXA 191 375
FIELD COMMUNICATOR

DXR 375
oder
DXR 375

98 Installation and Operations Manual

7532 Appendix

On-site operation:
• with display and operating module VU 331,
• with a Personal Computer, FXA 193 and the operating software ToF Tool.
The ToF Tool is a graphical operating software for instruments from Varec that operate
based on the time-of-flight principle (radar, ultrasonic, guided micro-impulse). It
assists with commissioning, securing data, troubleshooting, and documentation of the
measuring point.

Remote operation:
• with HART handheld DXR 35,
• with a Personal Computer, Commubox FXA 191 and the operating software
COMMUWIN II respectively ToF Tool.
• With a Personal Computer, TSM (Tank Side Monitor) and the operating software
FuelsManager.

System integration via Rackbus

Multiple 7500 RTG (or other instruments) can be connected to a higher-level bus system
via a Gateway ZA:
• Every HART transmitter via one interface module FXN 672 each.
• Gateways are available for MODBUS, FIP, PROFIBUS, INTERBUS etc.
• Both on-site as well as remote operation are possible.

L00-FMR53xxx-14-00-06-en-003

Integration into the Asset Management System

The HART interface allows the integration into the AMS® (Asset Management System)
from Fisher-Rosemount.

99
Appendix Radar Tank Gauge

11.4.3 Custody transfer mode

7500 RTG is a weight and measure approved level transmitter. Either the innage or the
ullage can be selected as the custody transfer variable.

The selected variable is the basis for the subsequent calculation of the current amount
of product in a tank, along with other measured variables such as (average) temperature
and pressure.

This opens up numerous application options in custody transfer:

• Quantity calculation of mineral oils
• Quantity calculation of alcohols

11.4.4 Weight and measure approval, Standards Authorities ap-

proval, Compulsory reapproval
The type approvals for custody transfer issued by the PTB and NMi, a copy of which is
enclosed with every device, prove the fundamental suitability of the various types for
custody transfer.

In addition to this, the accuracy of every single device is documented using a calibration
certificate, which is issued in the factory after the device has been tested on a reference
test rig.

On request, a separate initial verification of the devices can be carried out with a
National Standards Authorities inspector present, who issues a preliminary test certifi-
cate for every device. In the initial verification, the device is tested to ensure that it com-
plies with the limit of error in legal metrology, which lies at +-2mm for radar measuring
devices in Germany.

Essentially, this proves that the devices are weight and measure approved. The devices
must not, however, be used in custody transfer mode straight away.

The measuring device is not approved until after the approval after installation by the
Standards Authorities. For this, the device's level measurement is compared with the
tank gauging by a National Standards Authorities inspector using manual dips (also "Ini-
tial verification"). As a rule, a quiescent tank gauging is dipped by hand three times in a
row and then compared with the value displayed by the level radar. Depending on
national regulations, the transfer error limit, calculated as the arithmetic mean of the
absolute deviations of all three measurements, must not exceed double the limit of error
in legal metrology (compare, for example, the German "Eichordnung" or the American
"API 3.1B", in which the necessary procedures are also defined).

Depending on national regulations, this test is repeated with various tank gaugings.
Using linearization tables to compensate any non-linearities that occur in measurement
is permitted. For this, the 7500 RTG level radar offers a special dip table, compare
“Mounting calibration with VU 331” on page 57.

After the measurement has been approved by an inspector, he seals the level radar at
the stamp position and thereby also secures the programming status of the device.

Those operating an approved level transmitter are obligated to obtain reapproval in

accordance with the applicable national regulations from the Standards Authorities.

100 Installation and Operations Manual

7532 Appendix

11.4.5 Particularities in "approved" operation

The 7500 RTG level radar is set to custody transfer mode after commissioning using a
custody locking switch (see page 36). The position of the custody locking switch is
secured and sealed using the sealing pin.

During custody transfer measurement, all custody transfer-relevant functions for

operation are automatically locked, so that the device software can not be used, either
via local operation or via digital communication settings. This locked status is displayed
by the key symbol ( ).

7500 RTG radar devices continuously monitor the compliance with accuracy
requirements for custody transfer measurements according to OIML R85. If, for
example, the accuracy cannot be maintained due to quick surface movements, this is
reported via a separate alarm in the local display (displays "#" symbol) and via digital
communication.

11.4.6 Definition of terms

For definitions and procedures please refer to the following documents:

• Manual of Petroleum Measurement Standards, Chapter 3 - Tank Gauging,

Section 1.B - Standard Practice for Level Measurement of Liquid Hydrocarbons in
Stationary Tanks by Automatic Tank Gauging, American Petroleum Institute, second
edition, 2001

• OIML R 85, Organisation Internationale de Métrologie Légale, International

Recommendation R 85, edition 1998 (E)

101
Appendix Radar Tank Gauge

11.4.7 Integrated on tank gauging system

The Varec Tank Side Monitor 4590 provides integrated communications for sites with
multiple tanks, each with one or more sensors on the tank, such as radar, spot or
average temperature, capacitive probe for water detection and/or pressure sensors.
Multiple protocols out of the Tank Side Monitor guarantee connectivity to nearly any of
the existing industry standard tank gauging protocols. Optional connectivity of analog
4...20 mA sensors, digital I/O and analog output simplify full tank sensor integration.
Use of the proven concept of the intrinsically safe HART bus for all on-tank sensors
yields extremely low wiring costs, while at the same time providing maximum safety,
reliability and data availability.

Fuels Manager
Software 7500 RTG

HART
4 wire

RTU 8130
(remote
terminal
unit) Tank Side Monitor
Supply voltage:
16…253 VAC

L00-FMR53xxx-14-00-06-en-004
Pressure

This product may be protected by at least one of the following patents.

• US 5,387,918 i EP 0 535 196

• US 5,689,265 i EP 0 626 063
• US 5,659,321
• US 5,614,911 i EP 0 670 048
• US 5,594,449 i EP 0 676 037
• US 6,047,598
• US 5,880,698
• US 5,926,152
• US 5,969,666
• US 5,948,979
• US 6,054,946
• US 6,087,978
• US 6,014,100

Further patents are pending.

102 Installation and Operations Manual

Radar Tank Gauge Index

Index

A Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 G
Antenna extension . . . . . . . . . . . . . . . . . . . . . . . 75 Green LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Antenna size . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Group selection . . . . . . . . . . . . . . . . . . . . . . . . . 31
Approval after installation . . . . . . . . . . . . . . . . . 100
Auto-correction . . . . . . . . . . . . . . . . . . . . . . . . . . 57
H
Handheld unit DXR 275 . . . . . . . . . . . . . . . . . . . 41
B HART . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–29, 41
Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Housing T12. . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Basic Setup VU 331 . . . . . . . . . . . . . . . . . . . . . . 49
Blocking distance . . . . . . . . . . . . . . . . . . . . . . . . 16
I
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Initial verification. . . . . . . . . . . . . . . . . . . . . . . . 100
Installation in stilling well . . . . . . . . . . . . . . . . . . 11
C Installation in tank (free space) . . . . . . . . . . . . . 11
Cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Interference echo . . . . . . . . . . . . . . . . . . . . . . . . 54
Calibration to regulatory standards disturbed . . . 35 Interference echo mapping . . . . . . . . . . 54–55, 68
CE approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
K
Check distance . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Key assignment . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . 73 L
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 53
Communication symbol. . . . . . . . . . . . . . . . . . . . 35
Liquid crystal display (LCD) . . . . . . . . . . . . . . . . 34
Commuwin II . . . . . . . . . . . . . . . . . . . . . . . . . 43, 75
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Commuwin II-Operating Programm . . . . . . . . . . 43
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Contrast settings . . . . . . . . . . . . . . . . . . . . . . . . . 36
Current consumption. . . . . . . . . . . . . . . . . . . . . . 28 M
Custody locking switch . . . . . . . . . . . . . . . . . 34, 36 Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–55
Custody mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Marker at instrument flange . . . . . . . . . . . . . . . . 17
Customer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Maximum measured error . . . . . . . . . . . . . . . . . 88
Measure value actualisation. . . . . . . . . . . . . . . . 48
D
Measured value . . . . . . . . . . . . . . . . . . . . . . . . . 49
Declaration of conformity . . . . . . . . . . . . . . . . . . 10
Measured value display . . . . . . . . . . . . . . . . . . . 31
Degree of protection . . . . . . . . . . . . . . . . . . . . . . 30
Measuring principle . . . . . . . . . . . . . . . . . . . . . . 87
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Measuring range . . . . . . . . . . . . . . . . . . . . . . . . 14
Dielectric constant. . . . . . . . . . . . . . . . . . . . . . . . 50
Medium conditions . . . . . . . . . . . . . . . . . . . . . . . 50
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Minimum level . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Dip Table Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Modification nameplate . . . . . . . . . . . . . . . . . . . 85
Dip table status . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dip value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Mounting calibration . . . . . . . . . . . . . . . . . . . 57, 70
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mounting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 53
N
E
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical symbols . . . . . . . . . . . . . . . . . . . . . . . . . 6
Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Empty calibration. . . . . . . . . . . . . . . . . . . . . . 46, 52
No.of decimals . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Envelope curve . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Notes on safety conventions and symbols. . . . . . 6
Error messages. . . . . . . . . . . . . . . . . . . . . . . . . . 40
O
F
Operating menu . . . . . . . . . . . . . . . . . . . . . . . . . 33
Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 37
Foam surface . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ordering structure . . . . . . . . . . . . . . . . . . . . . . . . 8
Full calibration . . . . . . . . . . . . . . . . . . . . . . . . 46, 52
Function groups . . . . . . . . . . . . . . . . . . . . . . . . . 33

IOM027FVAE0804 103
 Radar Tank Gauge

P Unlock parameter. . . . . . . . . . . . . . . . . . . . . 37–38

Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Phase evaluation . . . . . . . . . . . . . . . . . . 51, 57, 60 W
Pipe diam. corr. . . . . . . . . . . . . . . . . . . . . . . . . . 58 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Pipe diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Weather protection cover . . . . . . . . . . . . . . . . . . 75
Pivoting element. . . . . . . . . . . . . . . . . . . . . . . . . 24 Weight and measure approved . . . . . . . . . . . . 100
Post-installation check . . . . . . . . . . . . . . . . . . . . 24 Weld seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power consumption . . . . . . . . . . . . . . . . . . . . . . 28 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power supply fails . . . . . . . . . . . . . . . . . . . . . . . 48
Process conditions . . . . . . . . . . . . . . . . . . . . . . . 51
Product class . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Q
Quick wiring guide . . . . . . . . . . . . . . . . . . . . . . . 25

R
Range of mapping . . . . . . . . . . . . . . . . . . . . . . . 55
Reapproval. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Recommendations for the stilling well . . . . . . . . 17
Red LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Reference point of measuring . . . . . . . . . . . . . . 46
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Reset customer parameters . . . . . . . . . . . . . . . . 39
Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
RF approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

S
Safety conventions. . . . . . . . . . . . . . . . . . . . . . . . 6
Sample hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . 10
Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Select the language . . . . . . . . . . . . . . . . . . . . . . 45
Selection menu . . . . . . . . . . . . . . . . . . . . . . . . . 31
Service adapter FXA 193 . . . . . . . . . . . . . . . . . . 75
Slot width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Smallest possible measuring range . . . . . . . . . . 14
Software history . . . . . . . . . . . . . . . . . . . . . . . . . 86
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Stilling well . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 53
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Switching on the measuring device . . . . . . . . . . 45

T
Tank Gauging . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Tank shape. . . . . . . . . . . . . . . . . . . . . . . . . . 49, 67
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Terminal compartment . . . . . . . . . . . . . . . . . . . . 28
ToF Tool . . . . . . . . . . . . . . . . . . . 41, 66, 69–70, 91
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . 77
Trouble-shooting instructions . . . . . . . . . . . . . . . 77
Turn housing . . . . . . . . . . . . . . . . . . . . . . . . 11, 19

U
Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

104 Installation and Operations Manual

7532

Notes

IOM027FVAE0804 105
 Radar Tank Gauge

Your offical representative

www.varec.com
Varec, Inc.
5834 Peachtree Corners East, Norcross (Atlanta), GA 30092 USA
Tel: +1 (770) 447-9202 Fax: +1 (770) 662-8939