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Operation Manual

OPW Fluid Transfer Group Europe B.V.

Rack Monitor 8800E/8801E

Version A.7

Date 16 June 2011

Summary of Contents for OPW Fluid Transfer civacon 8800E

Page 1: ...Operation Manual OPW Fluid Transfer Group Europe B V Rack Monitor 8800E 8801E Version A 7 Date 16 June 2011 ...

Page 2: ...Rack Monitor 8800E 8801E Document Operation Manual Date 16 Jun 2011 Version A 6 Page 2 of 35 H71343 This page is left blank intentionally ...

Page 3: ... pages of this manual should be present in accordance to the table of contents If not please contact the OPW Fluid Transfer Group Europe BV COPYRIGHT 2007 The design drawings and documentation are the exclusive property of OPW Fluid Transfer Group Europe BV It is submitted on the condition that the designs contained therein are held confidential and is subject to return on demand Apart from except...

Page 4: ...excess of the amount of invoice for the products THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED AND SPECIFICALLY THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Approvals The 8800E 8801E CIVACON Loading Rack Monitor is suitable for Equipment group II category 2 1 Class I Division 1 Groups C D hazardous locations with intrinsically safe outputs and housed...

Page 5: ...to the following specifications EN 60079 0 Electrical apparatus for explosive gas atmospheres Part 0 General requirements EN 60079 11 Electrical apparatus for explosive gas atmospheres Part 11 Intrinsic safety i EN 60079 1 Electrical apparatus for explosive gas atmospheres Part 1 Flameproof enclosures d EN 61000 6 2 Generic standards Immunity for industrial environments EN 61000 6 4 Generic standa...

Page 6: ...uts 9 Outputs 9 External environment reminder see installation manual for details 10 Product Description 11 Front layout 12 LED electronic light indicator Display info at power up 13 LED Display info 14 Sensors Types 15 Sensors and Grounding 15 System operation 16 Normal operation 17 Liquid Crystal Display 17 Sensor detection 20 Bypass operation 22 8800E Interior 23 Firmware upgrade 24 Event log 2...

Page 7: ...5 H71343 Data communications 26 Table 4 27 Table 5 27 Table 6 28 Table 7 28 Products 29 Supplied accessories 29 Optional system accessories 29 Maintenance 30 Check Points 30 Troubleshooting 31 Annex A Additional Electrical Drawings 33 Annex B Recommended Spare Parts 33 Annex C Certificates 34 ...

Page 8: ...ounted onboard control monitor or sensors The 88xxE rack monitor supersedes the 84xx and 85xx type rack monitors and are suitable for hazardous locations with intrinsically safe outputs There are two versions available The Rack Monitor 8800E is a complete version with liquid crystal display And the Rack Monitor 8801E version without a liquid crystal display The installation of both versions is the...

Page 9: ...lly safe normally closed input latched or un latched Outputs Permit Relay output Voltage 250V ac dc Current limitations 5AT Internal Fuses Functional specs Form A Normally open safety relay contacts energized when rack monitor overfill circuit is permissive Ground verification Relay output Voltage 250V ac dc Current limitations 5AT Internal Fuses Functional specs Form A Normally open relay contact...

Page 10: ...lation manual for details Operating Temperature Range Ta 45 C 42 8 F to 70 C 158 F Storage Temperature 8800E Ts 20 C 4 F to 70 C 158 F Storage Temperature 8801E Ts 45 C 42 8 F to 70 C 158 F The storage and transport ambient temperature of the 8800E may never exceed the above mentioned temperature range to prevent damage to the liquid crystal display The 8801E Rack monitor can be stored at Operatin...

Page 11: ...s of a large multi languages Liquid Crystal Display and Light Emitting Diodes indicators LED A clear and short message will be shown on the Liquid Crystal Display to explain the status of the overfill sensors cabling and Rack monitor The 8801E monitor is designed to be used where environment does not meet the necessary temperature specifications when the monitor is switched off Note For simplicity...

Page 12: ...ars are used to interface with the user The upper bar is indicating the status of the ground verification Second bar is indicating the internal communication of the electronics The Yellow indicators on the third bar are flashing if a bypass is activated The Red indicator will flash if a internal system error is detected The remaining Red bar and Green bar are indicating the status of the sensors ...

Page 13: ...rror indicator 6 Left Yellow Bypass indicator 7 Right Yellow Bypass indicator 8 Middle Red System error indicator 9 Red bar Compartment 1 till 12 indicators 10 Green bar Compartment 1 till 12 indicators All indicators have been switched on and off and the LED display is ready to receive sensor data from the main controller When no truck is connected all Red compartment indicators shall be on and a...

Page 14: ...ent are flashing and wet compartments are continuous on Yellow indicators inversely flashing Five Wire sensors Getting permissive Connect Plug Red compartment indicators are continuous on White earth indicators inversely flashing if ok Green indicators amount of dry detected compartments the red indicators will be switched off and truck is permissive to load Getting wet during loading e g 6 compar...

Page 15: ...rtment The 8800E can handle more then 12 compartments but only 12 will can be indicated on the LED display Maximum 12 compartments according EN13922 The 8800E will try to determine which compartment is wet if more than 12 compartments are used and if a good connection is made between plug and socket and wiring are done carefully the 8800E shall indicate the correct compartment on the Liquid Crysta...

Page 16: ...n sensors and shorts to ground for every channel and for open circuits Then the 8800E Rack Monitor will determine sensor type and the amount of compartments It can detect up to eight thermistors or Two Wire sensors up to 12 Five Wire sensors and is fully compatible with the 3204E Onboard Retain Overfill Monitor If possible the amount of sensors will be shown on the Display and Led indicators see s...

Page 17: ...ed and the plug is removed from the truck it will wait 15 minutes before it goes back to sleep Liquid Crystal Display Liquid Crystal Display info at power up After power up the following messages will sequential appear on the LC Display 01 P O W E R U P S E Q U E N C E S T A R T E D 02 03 D i s p l a y B o a r d 04 H a r d w a r e V e r s i o n 0 1 0 05 F p V e r s i o n 0 0 3 06 S o f t w a r e V...

Page 18: ...of the detected sensors Dry If all sensors are dry and a proper ground is verified the indication permit to load will appear at line 10 If less then 8 sensors are connected and the remaining sensors are emulated with a dummy the rack monitor will indicate the remaining channels as dry Two Wire sensors Note only when special Dummy is mounted in the socket of the Tank Truck Else remaining channels w...

Page 19: ... E D 1 2 07 S E N S O R S T A T E D R Y 08 09 10 P E R M I T T O L O A D It can happen that during loading a sensor get wet In this case the display will indicate the following e g 12 compartment truck with ground loop and Five Wire sensors and sensor in compartment 4 becomes wet 01 S Y S T E M R E A D Y E N 1 3 9 2 2 02 S O C K E T D E T E C T E D 03 04 G R O U N D V E R I F I C A T I O N B O L T...

Page 20: ... asked to accept the detected sensor by using the Blue bypass key Step 1 In this step the rack monitor is checking if all wires are connected to a sensor and there are no shorts between channels E g If on the tank truck one sensor is connected to two pins on the socket or one dummy channel is used to emulate two dry sensors the Rack monitor will detect this as a short and show this on the LC Displ...

Page 21: ...this moment a Bypass Key is needed to start loading When the bypass key is used the rack monitor will leave the NEN EN 13922 mode and the message EN13922 on the LC Display will be replaced with ROW Now the rack monitor has switched to the Rest Of the World mode See bypass chapter for details Note In EN13922 a bypass key is not allowed Therefore when a bypass key is used the rack will always leave ...

Page 22: ...separate earth cable The 8800E 8801E bypass routine is able to bypass more then one event stackable bypass This means every time a non permissive situation occurs except ground verification the rack monitor can be set back to permissive to load by placing the bypass key in the designated location see Bypass key manual for details The wet or faulty condition will stay visual until the plug is disco...

Page 23: ... all relay GND OK PERM AUX1 AUX2 RS485 422 TCP IP 5 X10 0 X1 5 0 Figure 2 A schematic drawing of the interior is shown above in Figure 2 Close to the relays and output terminals is the data communication hardware switch situated At the bottom right side of the sensor terminal inputs the address rotary selector is placed Beside the address selector a colour coded function switch see label on the in...

Page 24: ...r at the first screen after power up Event log If the 8800E 8801E rack monitor is provided with a SD card all loading events are stored time stamped The 8800E 8801E Rack monitor has his own Real Time Clock factory set to Greenwich Mean Time GMT Note GMT does not change with daylight savings time The event file is stored as a CSV file with the name Rackmon log A minimum of three events are stored e...

Page 25: ... one driver and multiple receivers multi drop or one receiver and multiple drivers The maximum of 32 devices is defined based on the Unit Load UL of each device 12K ohms The maximum devices on the net may be increased if the devices represent less then the UL fractional unit load A number of devices are being produced which represent 1 4 or 1 8 the unit load A maximum of 256 device could exist on ...

Page 26: ...other protocols are supported Ask OPW Fluid transfer Group for latest development Civacon 8500 Protocol Message Format STX A1A2 Command_Text ETX LRC Where STX Start of Text 02 Hex A1A2 Address 01 99 Hex Command Text Character string including Command Code and associated parameters ETX End of Text 03 Hex LRC Longitudinal Redundancy Check An underscore _ 5Fh is used as a command Text delimiter The L...

Page 27: ...age S T XAA OS_C1C2C3C4C5 E T X LRC Where C1 C5 are defined in Tables 4 7 Character C1 Definition Table 4 Character Hex Sensor Ground Ground Value Permit Verified Loop 0 30 6 36 X X 3E X X X X indicates an asserted condition Character C2 Definition Table 5 Character Hex 2 Wire 5 Wire Return Value Sensors Sensors Pulse 0 30 4 34 X 5 35 X X 8 38 X X indicates an asserted condition ...

Page 28: ...3 Sensor 2 Sensor 1 C3 Value Sensor 8 Sensor 7 Sensor 6 Sensor 5 C4 0 30 1 31 X 2 32 X 3 33 X X 4 34 X 5 35 X X 6 36 X X 7 37 X X X 8 38 X 9 39 X X 3A X X 3B X X X 3C X X 3D X X X 3E X X X 3F X X X X X indicates a wet sensor Character C5 Definition Table 7 Character Hex Sensor 12 Sensor 11 Sensor 10 Sensor 9 Value 0 30 1 31 X 2 32 X 4 34 X 8 38 X X indicates a wet sensor ...

Page 29: ...ls Supplied accessories A blue IR key is supplied to bypass the rack monitor except ground verification A special RED IR key to retrieve system diagnostic information Function key manual Installation and Operation manual Optional system accessories 7100E Blue Plug and 10 conductor individual screened coiled cable 7215E 10 conductor individual screened coiled cable 7450E Passive storage hanger 75x0...

Page 30: ...partial disassembling could be necessary the same risks and procedures apply as during installation Check Points During maintenance the following items should be checked All earth cables should rigidly connected and free from corrosion If there is no moisture inside of the enclosure If the main seal is still intact and still soft and smooth If there is no corrosion on any part inside the enclosure...

Page 31: ...se a premature or delayed shutoff of the loading procedure If the 8800E Rack Monitor does switch to the permissive state it will show the most probably cause on the LC Display The 8800E findings are based on the measured data and its conclusion might not be the correct conclusion In this unlikely case the Red Bypass Key must be used to show the most relevant sensor data on the Diagnostic screen on...

Page 32: ...roken Replace the fuses for new ones System goes directly into NON PERMISSIVE The dead man switch is not connected Connect the cable according to the installation manual Connect a bypass wire between pin 1 2 according to the installation manual System does not indicate correct amount of compartments in 5 Wire mode bad connections in sensor housing and or plug socket Check green and white wires Cle...

Page 33: ...ven parts but they have been known to be necessary to resume working swiftly after replacing these parts The recommended spare parts are Part number Description Quantity H71197 Main Seal 1 H71307 Corrosion Protector VCI 101 ACF 50 1 EL04141 Mains power input Fuse 2AT 1 EL04142 Relay contact output Fuses 5AT 1 The following parts are also available Part number Description Quantity EL04139 Liquid Cr...

Page 34: ...Rack Monitor 8800E 8801E Document Operation Manual Date 16 Jun 2011 Version A 6 Page 34 of 35 H71343 Annex C Certificates NEN EN ISO 9001 2000 Certificate Quality certificate ATEX certificate ...

Page 35: ...hat Product description Rack Monitor 8800E 8801E Item number 8800E 8801E Serial no Lot no Brand name Civacon has satisfactorily passed a manufacturing quality check containing a functionality test a dimensional check and a visual inspection All tests are in accordance with the OPW Fluid Transfer Group Europe BV General Test and Inspection Plan Place Nieuw Vennep Date Quality Control Inspector Auth...

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