EZ-FLO Weighing

You are here: Home / Vertical Tank Gauge Instructions

Vertical Tank Gauge Instructions

TONKA BAY INSTRUMENTS

Clarence Richard Company

3908 Tonkawood Rd - Minnetonka, MN 55343

Phone: (952) 939-6000   Email: david@clarencerichard.com

Tank Gauge

for level ranges above 12 feet

         

A) Installation

  1. Wall-mount TANK GAUGE indicator box in rain free environment.
  1. Attach (push in and pull back snugly) the sensing line (1/4 " nylon tube) to the bottom, rear port (Port B in Fig. 1-1) of TANK GAUGE to the connection on top of the Tank

Pipe.

  1. Attach a 1/4” nylon tube from a 100-psi pressure source (clean, dry air) to the remaining port (Port A) on the left side of the indicator box.
  1. When installed in a pressurized room (sealed control room with forced air heating and cooling); attach a sensing line from the bottom, front port (Port C) of the indicator box to the outside so the indicator box can ‘feel’ the same atmospheric pressure as  the vented tank.  Pressurized control rooms affect the accuracy of the TANK GAUGE, venting from the pressure of   ventilation systems becomes necessary.  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.  Locate outside tube end so air drawn in does not carry dust and dirt. This step is only necessary in cases where higher accuracy desired.

Vertical Tank Connection Two acceptable methods of sensing  the level of the tank may be available when plumbing the Tank Gauge instrument to the Vertical  Tank

Method A... Ground Level Check Valve ..Preferable.. The air passing through the spring loaded Check Valve allows the sensor to sense the level in the tank when attaching the sensing line to the bottom of the tank. The check valve is used to automatically shutoff the flow into the sensing line in cases the air flow from the Tank Gauge stops.  The plant compressor may be shutdown over night or over the week end with out a problem. Keep plumbing to check valve and shutoff valve as short as possible to allow heat from heated tanks to keep check valve operating.

A tube or pipe is connected from the check valve  and run upward to the top of the tank to contain any liquid from draining from the tank if ever the check valve should fail to close when the air supply is shut off..

Method B 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. Equipment, installation and maintenance costs of lengthy pipe  and if  a small separate compressor is required are disadvantages compared to Method A  Ground Level Check Valve. The  system can be installed with a full tank with the suspend pipe.

A) Tank Pipe Construction

  1. Use one continuous pipe (1” diameter pipe), from the top of the tank extending as far down as desired, to sense level changes. Do not weld or torch on oil tanks..Explosion!

2.          Hang the pipe from the top of tank so it may easily be changed if it cokes up. Coking only happens when the pressure is no longer supplied to the pipe. When the pipe is not being purged, oil rides up and down the inside of the pipe with the tank level, the oil cokes to the inside pipe wall. The air being supplied to the unit prevents coking from happening.  Dedicate a small oil less compressor for this application all season long.

 

B) Leak Check

1) Insert Tank Pipe into a nearly full tank (see B. above).

2) Connect sensing lines

3) Plug TANK GAUGE cord into electrical outlet  (120 +/- 10 VAC)

    4) Check for leaks with leak detector (one part dish soap to 1 part water) solution at  pipe and all tube connections. Upon power-up, the TANK GAUGE will perform a  "self test", and then read out in tenths of inches the uncalibrated height of the liquid level above the Tank Pipe bottom.

 

B)    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 Þ000, the gain value is 4.000.  Þ 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)

  1. 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.

A) Accurate Method: Draw liquid level below bottom of Tank Pipe

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

         TANK GAUGE.

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

bottom of the Tank Pipe.

  1. If reading is not correct simultaneously press the ▲(Increase) and ▼ (Decrease) button until the display reads ‘in’ (input).
  1. 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.

  1. 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”

  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)
  2. 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.
  1. Accurately determine the level of fluid from the bottom by tank "sticking" (measure with stick).
  1. 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'.
  1. 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"

  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

  1. Depress and hold INC and DEC until PARA is displayed.
  1. Toggle ‘ACK’ button to the numeric values just past 'AHi1',(High Level Alarm Set point) and set alarm trip point.
  1. Toggle to the numeric values just past 'ALo2' (Low Level Alarm Set point) and set alarm trip point.
  1. Toggle ‘ACK’ back to the ‘Normal ‘ mode level indication.
  1. 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.
  1. Acknowledge alarm by pressing 'ACK'.
  1. Replace tube to original position.
  1. 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'.
  1. 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.

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

a. 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

           b. Computer mis-calibration, failing electronics or extreme cold (viscous) material, internal pipe buildup, pipe plugging may indicate a             level higher than what is actually in the tank

c. 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.

  1. 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.

  1. 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.
  1. 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.
  1. List of default vales.

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.

AHi1........    High Alarm Set point

ALo1........    Low Alarm Set point

AHi2…….    High level shut off

In

inpt....... Curr

tYPE.......4 –20

Lin....... off

dP ....... 000.0

PVLo ....... 0.0                            

PVhi .......   207.2  high setpoint

FILT........    2.0  

oFST... 0 or above Low End Calibration Adjustment Factor  .2 affects reading by about 1 “

gain... about 4.000  High End Calibration Adjustment Factor .020 affects reading about 1 “

out

rLY1 ........ on

rLY2 ........ on

rEtr ........   off                  Set to on for retransmission then set high and low

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. Most 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

9)  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. Least accurate at lower tank levels but becomes very accurate at higher             levels. If 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 “.

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

8) 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

16) Repeat Steps 12-16 until satisfied.

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 these 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.