Horizontal Tank Gauge

TONKA BAY INSTRUMENTS

Phone: (952) 939-6000   Web: EzFloWeighing.com

Horizontal Tank Gauge

for level ranges up to 12 feet (ACK REV 5/02)

PATENT RIGHTS LICENSED TO TBI

 

A) Installation

1. Wall-mount TANK GAUGE indicator box.
2. Attach (push in and pull back snugly) the clear sensing line (1/4” nylon tubes) from the TANK GAUGE front port out to one of the two ports on the conductor pipe.
3. Attach the sensing line (1/4 “nylon tube) from the rear port of TANK GAUGE to the remaining port on the conductor pipe.
4. When installed in a control room; attach a sensing line from the middle port of the TANK GAUGE to the outside so the TANK GAUGE can feet the same atmospheric pressure as the vented tank. Pressurized control rooms affect the accuracy. So venting from the pressure of ventilation systems becomes necessary.

B) Horizontal Tank Connection

Suspended Pipe – Tank Roof Suspended Pipe. The back pressure being sensed is from the level of the oil. It is most important to keep pipe purged with air throughout the season otherwise the pipe will be clogged up with product and give a faulty reading. The  system can be installed with a full tank with the suspend pipe.

Conductor Pipe Construction

1. Use one continuous pipe extending from the bottom of the tank to at least a couple of

inches  above  the  top  of  the  tank. Bottom of Pipe End remains open.  A two  inch      diameter  pipe  is   recommended. Smaller diameter pipes may be used  when  larger  size  becomes  a  problem.

Note: Some materials build up inside the pipe over time slightly decreasing accuracy.

Pipe cleaning or replacement  corrects  the  problem.  Larger  diameter  pipes

won’t need cleaning or replacement as often.

2. Remove cap from tank  top.  Move  to  area  safe  for  torching  and  welding.  Open

       flames  around  asphalt  Tank  vents  and  manholes  cause  EXPLOSIONS!  Cut  a   hole

through the cap large enough to pass the pipe through.  Weld  pipe  securely  to  cap.

Pipe can be elevated off the tank bottom and computer can be  set  electronically  to

compensate for the elevated level by adjusting offset upwards. Consult  factory  when

drilled pipe holes are more than 20″ off tank bottom.

3. Apply Teflon pipe dope to customer supplied  female  TEE  and  two 1/4” tube fittings, and

assemble into a manifold attaching to the pipe top.

4. Attach red sensing line and  clear  sensing  line  from  TANK  GAUGE

to each side of conductor pipe TEE.

5. Allow pipe dope to dry.

C) Leak Check

1)    Insert Conductor Pipe into a nearly full tank .

2)    Connect sensing lines.

3)    Plug TANK GAUGE cord into  electrical  outlet  (120  volts  AC  plus  or

minus 10 VAC)

4)    Check for leaks with liquid soap solution at  conductor  pipe

TEE and all tube connections.

Upon  power-up  of  TANK  GAUGE  the  computer  will  perform  a  “self

test”, and then read out in tenths of inches the uncalibrated  height  of

the liquid level above the four pipe holes (drilled in B2 above).

D)  Introduction to Menu Navigation

     The Tank Gauge uses three buttons for programming/calibration purposes.  These buttons are: 1) ACK (ACKnowlege), 2) ▲ (increase), and 3) ▼ (decrease).

1. Upon powering-up the TANK GAUGE (after it has been properly installed) the read out will read the level the tank gauge can ‘see’. When this is the case you are in ‘RUN’ mode.
2. To exit ‘RUN’ mode and enter ‘PROGRAM’ mode you must press ▲ and ▼ The first category you will see displayed on the read out will be ‘PARA’, this stands for parameters.  To toggle through the more general categories (parameters, input, security, etc.) keep pressing ▲ and ▼ simultaneously.
3. When the category you wish to select is shown press ‘ACK’ to enter that category. Now, you are able to toggle through the options within the main category by pressing ‘ACK’.  To change the setting of an option, press ‘ACK’ until you see the option appears.  You will then see the value the option is set to (i.e. Gain  => 4.000, the gain value is 4.000.  => represents pressing the ‘ACK’ key).  To change a value use the increase and decrease keys (▲ and ▼ respectively).
4. When finished and to return to ‘RUN’ mode by displaying either an option or a category(NOT an option value) press ‘ACK’ and ▲ See the message ‘-buSy- displayed, the TANK GAUGE will then enter ‘RUN’ mode and the present level will be displayed.

 

(*note: values shown are only examples.  Keep Toggling through options by pressing ‘ACK’ key.  To change an ‘options’ value use ▲ or ▼.  To Enter Run Mode from program mode press ‘ACK’ and ▲ at the same time while a ‘Category’ or ‘Option’ is displayed.)

 

CALIBRATION PROCEDURES:

 

LOW END CALIBRATION:

1. Determine how far off the bottom of the tank the tank pipe is in inches. Document the

level here-   ______.__”(height of the bottom of the 1”  diameter Tank Pipe)

 

2. To perform the low-end calibration, use one of the following methods. Method A is the most accurate and is done when the oil level is below the bottom of the Tank Pipe.

Method B will be off by several inches at the bottom-end readings, but will become more

accurate as the liquid level approaches the high-end of the calibration level. Method B

            should only be employed for rough level estimates until Method A can be performed.

 

1. Accurate Method: Draw liquid level below bottom of Tank Pipe

1. Estimate Method: Remove the sensing line from the BOTTOM port (Port B) of the

         TANK GAUGE.

 

3. The TANK GAUGE should read a level equal to the distance from the Tank Bottom to the

bottom of the Tank Pipe.

 

4. If reading is not correct simultaneously press the ▲(Increase) and ▼ (Decrease) button until the display reads ‘in’ (input).

 

5. Depress and release (toggle) the ‘ACK’ button to the value just after ‘OFSt’.  This is

the offset value corresponding to the level read in 3. above.

 

6. Adjust the new ‘OFSt’ value by multiplying the error in inches by 2 (a fudge-factor), and adding or subtracting this number to the old ‘OFSt’ value.

 

Simply stated: New OFSt = (Existing OFST reading) minus (.2 times error)

Examples:

When the Tank Gauge reading is too low, increase the OFST value.

When the Tank Gauge reading is too high, decrease the OFST value.

 

Adjusting  the OFST value by .2 affects the level by about 1”

 

7. Toggle ‘ACK’ until the instrument reads tank level  (TANK GAUGE should read what tank level should be when liquid just covers the Pipe Holes)

 

8. If using Method B: When satisfied with the level indicated by the TANK GAUGE replace

 sensing line in (Port B) port of TANK GAUGE.

 

HIGH END CALIBRATION:

1. Vertical cylindrical tanks or applications where best accuracy near the top is

important, calibrate with tank level near full.

 

2. Accurately determine the level of fluid from the bottom by tank “sticking”

(measure with stick).

 

3. If TANK GAUGE does not read correctly, press and hold the INC button and

depress the DEC button until ‘in’ is displayed.  Toggle ‘ACK’ to the numeric

value just past ‘GAin’.

 

4. Adjust the values positive or negative depending on whether the TANK GAUGE

level reading is higher or lower than the stick reading according to the following

formula:

 

New ‘GAin’ Value =Tank Stick reading divided by TANK GAUGE

reading multiplied times Existing ‘GAin’ value

 

Or simply stated.-

 

[Stick/GAUGE] X Existing GAin = New GAin

 

Examples:

If TANK GAUGE reading is too low, increase GAin.

If TANK GAUGE reading is too high, decrease GAin.

Adjusting GAin by .020 affects the level by about 1″

 

5. Toggle the ‘ACK’ back to the ‘Normal’ mode level setting and compare new TANK

Gauge readings with tank level.  Repeat Steps 3-5 until desired setting is reached.

This formula gets the setting closer to the approximate target value.

 

HIGH/LOW LEVEL ALARM

1. Depress and hold INC and DEC until PARA is displayed.

 

2. Toggle ‘ACK’ button to the numeric values just past ‘AHi1’,(High Level Alarm

Set point) and set alarm trip point.

 

3. Toggle to the numeric values just past ‘ALo1’ (Low Level Alarm Set point) and set

alarm trip point.

 

4. Toggle ‘ACK’ back to the ‘Normal ‘ mode level indication.

 

5. Check the low alarm by disconnecting tube from bottom port of TANK GAUGE and

observing level indication falling to zero and sounding alarm 2 at trip point.

 

6. Acknowledge alarm by pressing ‘ACK’.

 

7. Replace tube to original position.

 

8. Check high-level alarm by adjusting its set point below the current level and return to Level

Readings.  Observe this trip point.  Silence alarm by pressing ‘ACK’.

 

9. Reset High Alarm trip point to desired set point and return to Level Readings.

 

NOTES:

Note: Some materials build up inside the pipe over time slightly affecting calibration. Continuous air purge eliminates this miscalibration problem.

 

1. Tank and TANK GAUGE instrument enclosure must be vented to atmosphere.

Pressurized tank and pressurized TANK GAUGE environment affects

signal.

 

2. Caution must be exercised when determining reliability of system installation.

 

1. Cut or pinched tubes, loose connections, computer miscalibration,

Low incoming air pressure or electronics failing may indicate a level lower

than what is actually in the tank

 

1. Computer miscalibration, failing electronics or extreme cold (viscous) material,

internal pipe buildup, pipe plugging may indicate a level higher than what is

actually in the tank

 

1. Tanks that are not level may cause incorrect readings, especially when the

conductor pipe is located at the end of a long tank and tank sticking is being done at

the opposite end.

 

3. Problems can occur when condensation forms in the tubes, especially when

exposed to freezing temperatures.  Care must be taken to keep these lines open and

clear by occasionally disconnecting both tubes from the instrument and forcing

clean, dry air through the tubes.

 

Should moisture become a problem: an air dryer may be used or tubes may be

positioned on a slope as much as possible so condensation can flow to a low area

where the operator can occasionally disconnect the tube to drain it.

 

Disconnect the tube at Top of Tank.  Verify airflow by feeling for air blowing

out end of tube, then reconnect. Replace tube back to normal position.

 

4. Accurate tank height and pipe offset dimensions are important for most accurate

readings. Please double-check this information.  Make sure pipe hangs straight

down when pipe length is used to estimate how far off the bottom  the tube end  level

location is.

 

5. When comparing tank sticking with TANK GAUGE readings, make sure tank

sticking procedure is consistent (to ensure consistency, it is advisable that the same

individual do the “sticking” each time).  Should problems occur with regard to

accuracy, please document TANK GAUGE as well as Stick readings twice at all

three tank levels (Low, Middle, High) when calling the factory.  This information

is used to determine whether problem was caused by installation, calibration or

equipment malfunction.

6. List of default values.

Values in bold should not be changed. Values underlined are set to users specifications.

 

PArA

PEAK…….    Highest tank quantity since last reset

VALY…….    Lowest tank quantity since last reset

(to reset VALY or PEAK to current tank quantity, hold down the INC key

while  touching the DEC key . When  the value is displayed, then release both keys.

AHil……..    High Alarm Set point     

ALo1……..   Low Alarm Set point

ALhi2          over fill high alarm set point

In

inpt……. Curr

tYPE…….4 –20

Lin……. off

dP ……. 000.0

PVLo ……. 0.0 

PVhi …….   207.6

FILT……..    2.0

oFST…….. Low End Calibration Adjustment Factor  .2 affects reading by about 1 “

gain  …….. High End Calibration Adjustment Factor( about 4.000)   .020 affects reading

about 1”   or leave at 1.00  and adjust PVHi

 

out

rLY1 …….. on

rLY2 …….. on

rEtr ……..   off

ALAr

AC-1 …….. High

Aou1 …….. rLY1

Lch1 …….. off

Ack1 …….. on

Adb1 …….. 2.0

Apu1 …….. NoAl

AC-2 …….. lo

Aou2 …….. rLY2

Lch2 …….. off

Ack2 …….. on

Adb2 …….. 2.0

Apu2 …….. noal

CAL

PULC  …….. 0.000

SEC

CodE  ……..  0

S.Par  ……..   off

S.Con  ……..  off

S.CAL  …….. off

7. CALIBRATION SUMMERIZED

 

METHOD A. The more accurate method, but tank level needs to be below Tank

                                   Pipe Bottom and then tank level needs to be near full.

1)  Draw tank level below the Tank Pipe Bottom.

2)   Reading should be within .2″ from the Tank Pipe Bottom level____._” (Page 3, Step 1)

3)   If not within .2″, Press ▲/▼ until ‘in’ is displayed and press ‘ACK’.

4)   Continue pressing  the ‘ACK’ key to toggle options until you reach the value for OFST.

5)   OFST should indicate the number of inches the tank pipe is from the bottom of the tank

6)   ▲ or ▼  OFST value until the level indicated in

5) is displayed. A .2 OFST value change affects the leavel reading by about 1 “.

7)   Press ‘ACK’ and ▲ simultaneously to return to run mode.

8)   Repeat steps 3 – 7 until satisfied

• Next, measure the level in the tank by “sticking”.

10)  Compare the stick measurement to the level indicated by the Tank Gauge .

11)  If closer calibration is necessary, Press ▲/▼ until ‘in’ is displayed.

12)  Press the ‘ACK’ key to toggle options until you reach the value for GAin.

13)  Adjust New ‘GAin’ value to = [Stick/Gauge] X Old ‘GAin’

Remember, increasing ‘GAin’ value raises Tank Gauge reading

              and vice versa.  A ‘GAin’ adjustment of .020 affects the TANK GAUGE

               reading about. 1 “.

14)  )   Press ‘ACK’ and ▲ simultaneously to return to run mode.

15)  Compare Stick to Gauge again

16)  Repeat Steps 12-16 until satisfied.

 

METHOD B. Less accurate at lower tank levels, but becomes very accurate at higher             levels. If the tank is full, Method B is quick because tank can be Low End calibrated and

            then immediately High End calibrated.

1)   Disconnect sensing line from Bottom Port of TANK GAUGE

2)   Reading should be within .2″ from the Tank Pipe Bottom level____._” (Page 3, Step 1)

3)   If not within .2″, Press ▲/▼ until ‘in’ is displayed and press ‘ACK’.

4)   Press the ‘ACK’ key to toggle options until you reach the value for OFST.

5)   OFST should indicate the number of inches the tank pipe is from the bottom of the tank

6)   ▲ or ▼  OFST value until the level indicated in 5) is displayed. A .2 OFST value change affects the leavel reading by about 1 “.

• Press ‘ACK’ and ▲ simultaneously to return to run mode
• Repeat until satisfied and replace tube in Port B (Rear port)

9)   Next, measure the level in the tank by sticking the tank.

10)  Compare Stick measurement to Tank Gauge reading.

11)  If closer calibration is necessary, Press ▲/▼ until ‘in’ is displayed.

12)  Press the ‘ACK’ key to toggle options until you reach the value for GAin.

13)  Adjust New ‘GAin’ value to = [Stick/Gauge] X Old ‘GAin’

Remember, increasing ‘GAin’ value raises Tank Gauge reading

              and vice versa.  A ‘GAin’ adjustment of .020 affects the TANK GAUGE

               reading about. .5 “.

14)   Press ‘ACK’ and ▲ simultaneously to return to run mode.

15)  Compare Stick to Gauge again

• Repeat Steps 12-16 until satisfied.

 

 

 

 

 

NOTE: Use outside air tube when Tank Gauge is located in a pressurized

room.  In a sealed control room with ventilation fan drawing air from outside

the Tank Gauge will be less accurate if the middle port is not vented to

outside atmosphere.

 

Tank – Gauge info chart—

tape this to the inside of the Tank Gauge Door

Clarence Richard Company 952 929 6000

Tank  Information.. to be filled in pencil

Tank  Product  ___________ High Alarm___ “ Low Alarm___”

Height___” Pipe Bottom Leve or Check Valve Level ____”  Gain____”  Offset  _____”

 

Caution:

As with any measuring instrument, many things happen to make the work correctly.

It takes just one thing not to work right and the reading can be significantly wrong and operation decisions are made from this reading.

 

Please follow theses precautions.

User must be aware that system reads high when pressure tube-pipe  is plugging or plugged and will read low when tubes are cut or connections poorly sealed or line to sensor is plugged. Electronics fail and connection may become poor, calibration may not be completed correctly, etc;  causing readings to be wrong.

 

Tank Gauge and Clarence Richard Company or associated dealers are to be held harmless for any calibration, equipment malfunction or operating problems. User must understand the equipment and limitations;  in order to confirm proper operation, the  user shall analyze all methods possible to them to assure the instrument is reading correctly by means such as comparing amount filled in tank and expected amount used and to visually check levels.