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
- Wall-mount TANK GAUGE indicator box.
- 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.
- Attach the sensing line (1/4 “nylon tube) from the rear port of TANK GAUGE to the remaining port on the conductor pipe.
- 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
- 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.
- 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.
- 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.
- Attach red sensing line and clear sensing line from TANK GAUGE
to each side of conductor pipe TEE.
- 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).
- 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.
- 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.
- 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).
- 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:
- 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)
- 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.
- Accurate Method: Draw liquid level below bottom of Tank Pipe
- Estimate Method: Remove the sensing line from the BOTTOM port (Port B) of the
TANK GAUGE.
- The TANK GAUGE should read a level equal to the distance from the Tank Bottom to the
bottom of the Tank Pipe.
- If reading is not correct simultaneously press the ▲(Increase) and ▼ (Decrease) button until the display reads ‘in’ (input).
- 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.
- 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”
- Toggle ‘ACK’ until the instrument reads tank level (TANK GAUGE should read what tank level should be when liquid just covers the Pipe Holes)
- 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:
- Vertical cylindrical tanks or applications where best accuracy near the top is
important, calibrate with tank level near full.
- Accurately determine the level of fluid from the bottom by tank “sticking”
(measure with stick).
- 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’.
- 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″
- 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
- Depress and hold INC and DEC until PARA is displayed.
- Toggle ‘ACK’ button to the numeric values just past ‘AHi1’,(High Level Alarm
Set point) and set alarm trip point.
- Toggle to the numeric values just past ‘ALo1’ (Low Level Alarm Set point) and set
alarm trip point.
- Toggle ‘ACK’ back to the ‘Normal ‘ mode level indication.
- 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.
- Acknowledge alarm by pressing ‘ACK’.
- Replace tube to original position.
- 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’.
- 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.
- Tank and TANK GAUGE instrument enclosure must be vented to atmosphere.
Pressurized tank and pressurized TANK GAUGE environment affects
signal.
- Caution must be exercised when determining reliability of system installation.
- 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
- 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
- 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.
- 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.
- 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.
- 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.
- 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
- 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.