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Varec 2500 Automatic Tank Gauge Service Manual

1. Item Part Description 19 DA4044 Counter Cover Assembly includes items 53 amp 54 20 02 08815 Gaugehead Body 21 BM18849 100 Imperial Counter Assembly 21m BM18850 100 Metric Counter Assembly 22 P14 146 O Ring 23 P10 2 Retaining Ring 3 24 P25 16 Pinion Gear 25 B7300 005 Tape Keeper Spring 26 P14 23 O Ring Seal 27 P31 669 Binding Head Mach Screw 28 P031 04 1697 Set Screw 29 P10 29 Grip Ring 31 P13 20 Bushing 2 33 02 08543 Washer 34 P030 04 822 1 2 NPT Plug 35 P30 237 Y NPT Plug 36 P031 32 1661 Washer 37 B4847 005 Washer 38 P031 05 1721 Hex Head Cap Screw 39 P031 07 1679 Rd Head Mach Screw 40 P031 01 1719 Binding Head Mach Screw 41 P31 247 Hex Jam Nut 42 P31 612 Hex Socket Set Screw Cup Pt 43 P031 08 1720 Self Tap Screw 44 P31 1 Washer 2 45 P31 13 Shim Washer 5 46 P030 04 802 3 8 NPT Plug 47 P031 05 1601 Hex Head Cap Screw 68 48 P1 5 Negator Motor Only BA7762 Negator Motor Sheave Assembly includes items 55x2 amp 56 49 P031 11 1807 HSCS not shown 51 06 10364 Tape Storage Sheave Assembly Cassette not shown 52 06 10490 Handle Crank not shown 53 P30 236 Top Counter 14 NPT Plug 54 B12759 003 Bottom Counter 4 NPT Drain Plug 55 02 09598 Bushing shoulder PTFE 4 56 B14872 101 Motor Top Plate 57 P31 671 Screw 58 P31 692 Screw 59 BM3784 Original handle Crank Not Sho
2. 56 114 1 1 2 inch NPT D 4 06 TRIN 103 Las di A Section A A Figure 4 29 Oil Seal 8 5 inch Water Column Operating Pressure Oil Seal Apply appropriate pipe thread compound and install long pipe 1 into 135 degree elbow with bottom drain 4 Apply pipe thread compound and install short pipe 2 into 135 degree elbow with bottom drain 4 Apply pipe thread compound and install 135 degree elbow 3 onto long pipe 1 Apply pipe thread compound and install 90 degree elbow supplied with gauge kit onto short pipe 2 Adjust the assembly to provide the tape tape cable path illustrated Provide 1 5 inch pipe installation as required Proceed with the remainder of the tank installation to the paragraph Initial Lubrica tion then fill the oil seal as follows A Remove the cover from 90 degree elbow B Fill to halfway in the short pipe Note To drain the oil open the plug in 135 degree elbow 4 Varec nc 53 In Service Installation Procedures Automatic Tank Gauge 4 3 Inspection Hatch and Manhole Cover Varec recommends the installation of a manhole or inspection hatch if there is not already one located within arm s reach of the tape pipe location 4 3 1 Inspection Hatch 1 Remove the cover to a safe welding location 2 Cutarectangular hole 6 00 inches x 15 75 inches 152 mm x 400 mm in the cover 3 Cuta 2 50 inch 6
3. 6 Section 3 16 Install Tape in the Gaugehead on page 36 7 Section 3 18 Reset the Counter on page 41 8 Section 3 19 Calibrate the Counter on page 42 9 Section 3 20 Initial Lubrication on page 43 10 Section 3 21 Install a Transmitter and Replace all Covers on page 44 11 Section 3 22 Initial Operation on page 45 12 Installation and Operations Manual 2500 ATG General Preparation 2 4 5 Tank Top Mounting Order Code T04 T14 T24 T32 Installation parts supplied include Gauge U bolt kit Guidewire bottom anchor Guidewires Gaugehead and tape Float Guidewire top anchors x2 Tape connectors Conduit connector kit 2 4 5 1 Installation Checklist When installing a 2500 ATG system on a cone roof tank complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Description Complete Section 3 2 Tank Roof Entry Cone Roof Tank on page 22 Section 3 6 Installing Anchors and Guidewires on page 26 Section 3 9 Installing a Roof Reading Gaugehead on page 29 Section 3 10 Float installation on an Out of Service Tank on page 30 Section 3 11 Connecting the Tape to the Float on page 31 Section 3 16 Install Tape in the Gaugehead on page 36 Section 3 18 Reset the Counter on page
4. o Drive Pin on Sprocket EE T Lol oi 5 5 o o o J Gaugehead Transmitter Sprocket Wheel and Tape Slotted Drive Coupling Figure 3 25 Transmitter Installation on a 2500 ATG Note The use of auxiliary units not manufactured or supplied by Varec will void any Varec mg warranty and will relieve Varec of any obligation to service the product under warranty Replace the back cover and its gasket Torque the back cover bolts to 6 ft Ib Do not over torque Replace the bolts gaskets and covers on the elbows Close the tank manholes and inspection covers Check the operation of the auxiliary unit as appropriate 44 Installation and Operations Manual 2500 ATG Installation 3 22 Initial Operation Caution Initial filling of the tank must be at a reduced rate of flow until the float travel and dial operation are verified This checks that the 2500 ATG was installed correctly and prevents possible damage to the gauge system Floating Roof Tanks On floating roof tanks this is particularly important because the tape travel has not been checked during the installation 1 Station an observer at the gaugehead 2 Begin filling the tank to raise the float several feet about three feet or one meter from the bottom Caution Do not release the checker knob and allow the springs to return the mechanism Over time the springs will break and jam the gauge Caution Do not turn the operation checke
5. 0 0 00 cee eee 3 1 3 2 CHECK Knob nuii tanned Sede RRA ERE X QE aya aed ah ee ye 3 1 8 8 Negator Cassette 2 ee eee 3 1 8 4 Bloat Cranks i223 fata aa irato atte mca gar Salva a tate a aaa ae 3 2 General Preparation issssuse 5 2 1 Safety Precautions 0 0 cee e 5 2 2 Tools Equipment and Materials 0 000 eee eee eee 5 2 3 Guidelines Recommendation and Options When Preparing for Installation 6 2 3 1 Floating Roof Tank Installations llle 6 2 3 2 Guidewires and Anchors llle eee 6 2 3 3 Support Brackets ve srenti a Sea E e T E E ees 7 2 3 4 Conduit Pipework and Couplings aaan eanan aaaea 7 2 3 5 Tank Roof Entry via Manhole amp Inspection Covers l l 8 2 3 6 Floats uie eR eR ERR ue E aT Sar ee ETRURIAE dE 8 2 4 Identifying Your Installation Type lille 9 2 4 1 Cone Roof Tank ia ian i xe mE e ead Fede RO eae aS 9 2 42 Bolted Tank i4 sedo estate aia bad ae wo Daa a ee eae RD md 10 2 4 3 Cone Roof Tank with Internal Floating Roof Pan and Floatwell 11 2 4 4 Cone Roof Tank and Internal Floating Roof Pan No Floatwell 12 2 4 5 Tank Top Mounting llle 13 2 4 6 Stilling Well Service Cone Roof Tank 6 Diameter Float 14 2 4 7 External Floating Roof Tank and Floatwell lessen 15 2 4 8 External Floating Roof Tank No Floatwell lesse 16 2 4 9 Interface Se
6. 2 Dothe same for the other top cable anchor 6 AM locking nut 3 Fixed nut i Tension S Adjusting nut 3E ei be 72 8 eo 2 a8 A A N p 1 1 4 Inch NPT plate assembly Half nipple Figure 3 13 Detail A Top Anchors 3 Remove the housing nipple and cap from the top cable anchors and hang plumb lines from their centers to mark the position where the bottom cable anchor will be welded to the tank floor Mark these positions on the tank floor 4 Mark the plumb bob string at the height of the tank bench mark This will assure that the plumb bob just touches the bottom when the reference is made from the bench mark distance to the bottom 5 Hang a plumb line through the center of the top tape pipe to the bottom to mark the float center This should be 8 50 inches 216 mm from each of the cable anchor positions previously marked on the tank floor 6 When the positioning has been checked weld the bottom cable anchor into place 7 Thread the float guide cables into the tank through the top anchor fittings Fasten them to the bottom cable anchor with the furnished hardware 25 2 00 5 00 6 51 127 25V 2 00 5 00 Guide clip e 54 127 Hex nut SA j Hex head cap screw D DETAIL B N Figure 3 14 Detail D Bottom Anchor Weight 8 Thread the upper end of each guide cable throug
7. 3 Install the other elbow on the horizontal pipe 4 Mountthe exterior vertical pipe into the support brackets and screw it into the upper elbow 5 Tighten the support bracket nuts 6 Remove the bolts covers and gaskets from the elbows B D 25 6 4 X 1 5 38 Steel flat bar 450 b Te 114 B 72 00 A 1829 Tape cable splice rL oL te e n A 1 2 13 Hardware i ey Q ER position tm e 47 75 i i B 7 cT PV 11243 Places Bw E n L J gam 1 1 2 Inch pipe and n m por e by customer ie 2 51 X 2 51 X 25 6 4 c Steel angle on cable splice View B B at full tank Maximum posiotion 914 16 00 Layout m pipe supports 406 spaced approximately at cnm 10 foot 3 meter intervals Typical 25 6 6 00 Typical 152 25 6 Convenient eye level Grade View C C RRR Figure 3 15 Example Support Bracket Installation Varec Inc 27 Installation Automatic Tank Gauge 3 8 Installing a Gaugehead at Grade Level Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Warning When removing the gaugehead back cover stand to one side as the last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed 1 Remove the back cover and gasket from the gaugehead Note The weight of the installed gaugehead is supported by the pipe and bra
8. 39 Installation Automatic Tank Gauge 3 17 Trimming the Cable at the Float in a Floatwell Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding 1 Check the tape tape cable path between the float and the gaugehead to be sure that it is not kinked or twisted 2 Check that the tape tape cable splice position is at the bottom end of the outboard elbow connection Caution Splice must reside in vertical pipe throughout the total travel of the roof If splice enters gaugehead gauge will hang up and damage will result If splice passes over elbow sheave the gauge may hang up or may cause the tape tape cable to become dislodged from the sheave 3 To adjust loosen the screws on the cable clamp while holding on to the cable Pull the cable through the clips while keeping the tape tension tight When splice is in proper position tighten the screws and release cable The spring motor will pull the tape taut 4 Check that the float is correctly positioned parallel to the waterline of the well then cut off the excess cable Caution Do not allow the float to fall back to the floor of the tank Damage to the float or tank may result 40 Installation and Operations Manual 2500 ATG Installation 3 18 Reset the Counter Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding To reset the dial
9. Automatic Tank Gauge clause In no case shall the Seller s liability exceed that stated as Limitations of Remedy in the contract between the Seller and Buyer Use of parts that are not manufactured or supplied by Varec voids any warranty and relieves Varec of any obligation to service the product under warranty Varec recommends the use of only Varec manufactured or supplied parts to maintain or service Varec 2500 Automatic Tank Gauges Terms of Use The information provided in this document is provided as is without warranty of any kind Varec Inc disclaim all warranties either express or implied including the warranties of merchantability and fitness for a particular purpose In no event shall Varec Inc or its suppliers be liable for any damages whatsoever including direct indirect incidental consequential loss of business profits or special damages even if Varec Inc or its suppliers have been advised of the possibility of such damages This manual is solely intended to describe product installation and functions and should not be used for any other purpose It is subject to change without prior notice This manual was prepared with the highest degree of care However should you find any errors or have any questions contact one of our service offices or your local sales agent Product Approvals This document and the information provided within are controlled by the approvals agency s listed below All changes to this
10. Manual of Petroleum Measurement Standards Chapter 3 Tank Gauging Section 1B Standard Practice for Level Measurement of Liquid Hydrocarbons in Stationary Tanks by Automatic Tank Gauging Installation and Operations Manual 2500 ATG Introduction 1 2 3 System Integration A range of analog and digital tank gauge transmitters is available that mounts directly to mechanical tank gauges Figure 1 3 2500 ATG with a 2900 Float amp Tape Transmitter Level measurement data is encoded by the transmitter and output via industry standard communications to the control room Some transmitters also offer spot temperature measurement integration that can be used for inventory control applications When a tank gauge transmitter is used communications and power are required at the gaugehead Varec transmitters do not require an adaptor flange When connecting third party equipment a specific adaptor flange depending on the transmitter is often required 1 3 Product Options 1 3 4 English and Metric Configurations Varec provides the following three measurement and display configurations English fractional feet inches 16ths English decimal feet inches 10Oths Metric configurations meters 10ths 100ths English reading gauges are manufactured with a reversible fractional decimal dial For example if the customer desires a decimal level display the dial can be removed reversed and reinstalled to s
11. The floatwell should contain a baffle to prevent the float from escaping while allowing sufficient product movement to equalize the liquid level No tape should be exposed outside of the roof or pipework If any section of the tape is currently exposed it should be replaced with a stainless steel flexible cable This will reduce measurement error due to wind drift The connector between the tape and cable should not run over a conduit elbow or pulley Note An internal floating roof is often referred to as a Pan e g a cone roof tank with a pan and floatwell Guidewires and Anchors Note Varec recommends guidewire installations or stilling well installations where possible Varec recommends guidewire installations for the 2500 ATG with standard guidewire centers of 17 432 mm when a standard 14 5 368 mm diameter Type 316 stainless steel hollow shell float is used Guidewires provide stability for the float during turbulent conditions and provide increased accuracy by reducing the horizontal movement of the float across the surface of the product The guidewires should be installed centered and free of twists or kinks Check the movement of the float for friction or impended movement before final operation Varec provides two options for tank bottom guidewire anchors in service and out of service anchors An anchor that can be welded to the tank bottom is used when the tank is out of service Part AA1025 A cast iron weig
12. 155 piece of tape Float Grounding Clamp Float Float Tape Clamp 2 required Gauging Tape formed into U A Avoid bending at hole 2 Tape connector Locking Tube formed into a U Avoid bending at hole O88 0 UL with ground connector without ground connector Figure 4 32 Tape Clamp Assembly 56 Installation and Operations Manual 2500 ATG In Service Installation Procedures 12 Attach the tape connector to the float pass it through the hatch and attach the eyes to the guide cables Caution Do not allow the float to fall back to the floor of the tank Damage to the float or 13 14 15 16 17 tank may result If necessary use an assistant to help secure the float so it does not fall Lower the float until it is hanging from the tape Inspect the tape and cables for twists and kinks Make sure that the cables are parallel then lower the float to the surface of the product Make sure there is sufficient slack tape inside the tank to allow float travel to the tank bottom check reference mark previously made Trim the tape about 6 feet 1 8 M from the bottom of the gaugehead Proceed per instructions in section 3 16 Install Tape in the Gaugehead on page 36 depending on the model Make a hand gauge measurement of the tank product level Use the bench mark reference to calibrate the hand gauge Use extra care to
13. 4 5 liters of oil are required To fill the counter assembly with oil it is necessary to change the bottom NPT condensate drain plug Replace it with a solid 1 4 NPT plug or reverse the top solid plug with the bottom plug Fill the hole in the condensate drain plug with Dow Corning RTV 737 sealant The counter assembly will hold approximately 1 06 quarts 1 0 liter The appropriate oil selected for lubrication may also be used in conduit oil seal units 7 9 Corrosion check Check for signs of corrosion Interior corrosion of the pipe carrying the tape may become deposited in the mechanism and affect the accuracy Varec Inc 71 Maintenance Routines Automatic Tank Gauge 7 10 Basic maintenance Basic maintenance should be conducted as required depending on the service conditions The basic maintenance kit provides all the recommended parts that may need replacing during such a procedure Follow the disassembly instructions in Chapter 6 when replacing any parts on the gaugehead 7 11 Extended maintenance Extended maintenance should be conducted as required depending on the service conditions The extended maintenance kit provides all the recommended parts that may need to be replaced during such a procedure Follow the disassembly instructions in Chapter 6 when replacing any parts on the gaugehead 7 12 Overhaul maintenance A complete gaugehead overhaul or refurbish should be conducted as part of an API 653 tank o
14. 44 and shim washers 45 as required Test that the sheave turns freely with less than 0 005 axial play for the Standard 2500 ATG and no axial play for models with crank or cassette Secure the motor storage sheave assembly 48 with retaining ring 23 Use washer 44 and shim washers 45 as required Test that sheave turns freely with 0 005 to 0 010 axial play Attach the spring motor to the tape storage sheave assembly and tighten screw Fig 3 1 item 7 Make sure the spring motor is not twisted out of alignment during screw tightening Refer to Chapter 3 Installation section 3 16 1 With a Negator Spring Motor on page 37 for winding the motor Open elbow sheave assemblies and inspect operation and condition Replace cover gasket defective sheaves and worn shafts as required Lubricate the shaft and sheave with a light oil To reinstall the tape or tape cable refer to Chapter 3 Installation section 3 11 Connecting the Tape to the Float on page 31 through section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 Proceed to section 6 3 Counter Wheel Assembly on page 67 66 Installation and Operations Manual 2500 ATG Gaugehead Disassembly and Re assembly 6 3 Counter Wheel Assembly If you remove the screws 43 and retainer from the counter wheel assembly 21 and the pinion gear 24 is disengaged you must remove the dial and pinion gear in order to reset the counter dru
15. 68 P30 105 Conduit Connector female end 1 8 8 Float Grounding Kit The Float Grounding Kit positively grounds the float to the tape or cable Connect the grounding cable A to the tape clamp point B and float point C as shown in figure 2 6 Table 8 13 Float Grounding Kit Item Part Description Qty 69 13 10974 Float Grounding Kit Float and Tape Clamps and Grounding Cable e b Tape Grounding Clamp sy T 9 a CI Il eg ue T CI A 2 required a m Grounding Cable N Gauging Tape formed into U A Avoid bending at hole y Tape connector Locking Tube 6 00 Inch 155 piece of tape formed into a U Avoid bending at hole E NY Leu oe ea ae N Float Grounding Clamp Float with ground connector Figure 8 10 Float Grounding Kit 86 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits 8 9 Other Accessories 8 9 1 Gauge Calibrator Assembly The Gauge Calibrator allows level transmitters with absolute encoders to be calibrated without disassembling the transmitter from the gaugehead The calibrator is accessed by removing the counter assembly cover By simply turning the calibrator the counter and the transmitter can both be set to the proper level The dual calibrator can be retrofitted to existing 2500 ATG installations Part 13 08948 8 9 2 Condensate
16. Float Guidewire top anchors x2 Tape connectors Conduit connector kit 2 4 1 1 Installation Steps Checklist When installing a 2500 ATG system on a cone roof tank complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Section Description and Page Number Complete 1 Section 3 2 Tank Roof Entry Cone Roof Tank on page 22 2 Section 3 6 Installing Anchors and Guidewires on page 26 3 Section 3 7 Installing Support Brackets amp Pipework on page 27 4 Section 3 8 Installing a Gaugehead at Grade Level on page 28 5 Section 3 10 Float installation on an Out of Service Tank on page 30 6 Section 3 11 Connecting the Tape to the Float on page 31 7 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 8 Section 3 16 Install Tape in the Gaugehead on page 36 9 Section 3 18 Reset the Counter on page 41 10 Section 3 19 Calibrate the Counter on page 42 11 Section 3 20 Initial Lubrication on page 43 12 Section 3 21 Install a Transmitter and Replace all Covers on page 44 13 Section 3 22 Initial Operation on page 45 Varec Inc 9 General Preparation Automatic Tank Gauge 2 4 2 Bolted Tank Order Code T05 T15 Installation parts supplied inclu
17. complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Description Complete 1 Section 3 2 Tank Roof Entry Cone Roof Tank on page 22 Section 3 6 Installing Anchors and Guidewires on page 26 Section 3 7 Installing Support Brackets amp Pipework on page 27 Section 3 8 Installing a Gaugehead at Grade Level on page 28 Section 3 10 Float installation on an Out of Service Tank on page 30 Section 3 11 Connecting the Tape to the Float on page 31 2 3 4 5 6 7 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 Section 3 16 Install Tape in the Gaugehead on page 36 Section 3 18 Reset the Counter on page 41 10 Section 3 19 Calibrate the Counter on page 42 Section 3 20 Initial Lubrication on page 43 12 Section 3 21 Install a Transmitter and Replace all Covers on page 44 13 Section 3 22 Initial Operation on page 45 Varec nc 17 General Preparation Automatic Tank Gauge 18 Installation and Operations Manual 2500 ATG Installation 3 Installation This chapter gives instructions for the various types of installations based on the order code options for the 2500 ATG Note Before installing your 2500 AT
18. 16 1 With a Negator Spring Motor lille 37 3 16 2 With a Negator Cassette 0 2 0 0 ees 38 3 16 3 With a Hand Crank Gaugehead 0 0 cee eee ees 38 Trimming the Cable at the Float in a Floatwell 04 40 Reset the Counter 0 0 0 cette eens 41 Calibrate the Counter liliis es 42 Initial Lubrication 2 2 llle III 43 Install a Transmitter and Replace all Covers slsulssun 44 Initial Operation 0 0 RII II ee 45 In Service Installation Procedures 47 Negator Cassette Installation 2l 49 AAA Disassembly J L eroe uter e o eR S PR RR Y en fan 49 4 1 2 Assembly ove c ex PX RR ORE E ek RUE RURAL ERR ae eee n 49 Oil Seal Installation lille 52 4 2 1 27 inch Water Column Operating Pressure Oil Seal LL 52 4 2 2 8 5 inch Water Column Operating Pressure Oil Seal 53 Inspection Hatch and Manhole Cover anassa naana cece ene eas 54 4 3 4 Inspection Hatch 2 0 ce ee 54 4 3 2 Manhole Cover lille 54 Guidewire Bottom Anchors 0 0c cece eee tees 55 In service Float amp Guidewire Installation 0 000 e eee eae 56 Operation ours kindy aut en A n te b banned vet bake Vs 59 Gaugehead Disassembly and Re assembly 61 Gaugehead Disassembly 000 00 e eee iles 61 Gaugehead Assembly 00 0 cece eee 65 Counter Wheel Assembly 0 00
19. 18 Tape Clamp Assembly with Grounding Cable Form a U at the end of the perforated tape Form it to match the U piece previously formed Do not kink Install the gauge tape and U piece to the tape connector with the tape clamps and screws provided making certain that the tape is not kinked or twisted Connect the grounding cable A to the tape connector point B Attach the tape connector to the float Connect the grounding cable A to the float point C Varec Inc 31 Installation Automatic Tank Gauge 3 12 Connecting the Cable to a Float in a Floatwell Note Note section 2 4 before proceeding to a cable At the outboard elbow feed the cable through the horizontal pipe over the tank entry elbow and down through the pipe to the floating roof Check that it is centered on the well Continue feeding the cable until the tape tape cable splice is reached Figure 3 19 Feed the cable and tape 2 Drop the tape end down through the outboard elbow vertical pipe and gaugehead to the ground cloth Feed out all tape until the tape tape cable splice is reached Position the splice at the bottom end of the vertical outboard elbow connection If the well is covered drill a hole in the floating roof to accommodate the cable and a suitable user furnished guidewire Enlarge the hole if one was made in the step above to accommodate a suitable user furnished guidewire Install the guidewire M
20. 3 20 Initial Lubrication on page 43 12 Section 3 21 Install a Transmitter and Replace all Covers on page 44 13 Section 3 22 Initial Operation on page 45 Varec Inc 11 General Preparation Automatic Tank Gauge 2 4 4 Cone Roof Tank and Internal Floating Roof Pan No Floatwell Order Code T07 T17 Installation parts supplied include 90 Elbow assembly x2 Gauge U bolt kit Support bracket x6 Gaugehead and tape cable Tape cable connectors Conduit connector kit 2 4 4 1 Installation Checklist When installing a 2500 ATG system on a Cone Roof Tank and Internal Floating Roof Pan without a Floatwell complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Note Due to the resulting gross measurement inaccuracies Varec does not recommend that the perforated tape tape cable be attached directly to a floating pan Use a covered floatwell for the best measurement accuracy Step Description Complete 1 Section 3 3 Tank Roof Entry Internal Pan Floating Roof on page 23 2 Section 3 7 Installing Support Brackets amp Pipework on page 27 3 Section 3 8 Installing a Gaugehead at Grade Level on page 28 4 Section 3 13 Connecting the Cable to a Floating Pan on page 33 5 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35
21. 57 amp 58 Figure 6 1 2500 ATG Gaugehead spare parts Varec Inc 61 Gaugehead Disassembly and Re assembly Automatic Tank Gauge Perform these steps to disassemble the gaugehead Note Disassemble the gaugehead only as far as needed to replace worn or defective parts Warning Vapors and possible flammables Make certain that the tank is empty and not in service Observe appropriate safety precautions in flammable or hazardous liquid storage areas Do not enter or access a tank that has contained hydrocarbons vapors or toxic materials until a gas free environment is certified Carry breathing equipment when entering or accessing a tank where oxygen may be depleted with carbon dioxide nitrogen or other gases Warning Electrostatic Charge Worker activity and worker clothing may accumulate electrostatic charges on the body of a worker Care should be used in flammable environments to avoid this hazard The mechanical connections between the guide cables float tape and gaugehead provide an electrical resistance path to ground that is adequate for the safe electrical drain of electrostatic charges that may accumulate in the tank and product 1 Ifthe gaugehead is oil filled drain the oil Warning Broken motor spring parts can cause injury Whenever the back cover of the gaugehead is removed stand to one side as the last bolt is removed If the motor spring is broken the broken pieces may cause injury when the cov
22. Assembly 15 B7796 005 Spring 16 B6547 005 Tape Keeper Post 21 BM18849 100 Imperial Counter Assembly 1 Imperial kit only 21m BM18850 100 Metric Counter Assembly 1 Metric kit only 22 P14 146 O Ring 23 P10 2 Retaining Ring 4 24 P25 16 Pinion Gear 2 25 B7300 005 Tape Keeper Spring 1 26 P14 23 O Ring Seal 1 27 P31 669 Binding Head Mach Screw 3 29 P10 29 Grip ring 1 31 P13 20 Bushing 1 33 02 08543 Washer 2 37 B4847 005 Washer 1 38 P031 05 1721 Hex Head Cap Screw 16 39 P031 07 1679 Rd Head Mach Screw 6 40 P031 01 1719 Binding Head Mach Screw 3 42 P31 612 Hex socket set screw Cup Pt 1 43 P031 08 1720 Self Tap Screw 3 44 P31 1 Washer 6 45 P31 13 Shim Washer 14 48 BA7762 Negator Motor Assembly includes items 55x2 amp 56 55 02 09598 Shoulder Bushing 2 56 B14872 101 Motor Top Plate 57 P31 671 Screw 58 P31 692 Screw 59 BM3784 Original handle Crank Not Shown 60 13 10974 006 Float Grounding Cable Not Shown AA BM5478 600 Tape Clamp Assembly BB A371 071 Sheave Elbow Cover Gasket 2 DD AA1025 Anchor Bottom for 2500 ATG and 6700 Liquid level Indicator Steel Varec nc 81 Spare Parts and Maintenance Kits Automatic Tank Gauge 8 4 1 Item Part No Description Quantity in kit na SRMOO1 Service Manual 1 Additional items When performing a complete overhaul or refurbish Varec recommends replacement of the tape or tape and
23. Reservoir The condensate reservoir is designed to collect condensate that would otherwise accumulate in the gaugehead Its use is recommended where an excessive amount of condensate could develop or in oil filled gauge applications Part DA4051 8 9 3 Shock Absorber The Shock Absorber reduces wear and maintenance on a 2500 ATG P by minimizing the transfer of wave energy from the float to the perforated tape and gaugehead components It prevents the float from becoming detached from the tape by wave action and should aa always be used in tanks with turbulent conditions near inlet or outlet piping and near a mixer Part DA6138 8 9 4 Teflon Tape Wipe The Tape Wipe mounts in the conduit between the top of the tank and the first elbow and removes excess residue from the tape It minimizes vapor loss from the tank into the conduit and helps prevent vapors and liquids from contaminating the gaugehead Part BA13924 Varec Inc 87 Spare Parts and Maintenance Kits Automatic Tank Gauge 88 Installation and Operations Manual 2500 ATG Troubleshooting 9 Troubleshooting Friction is acommon problem that affects gauge accuracy Some liquids produce corrosion in the mechanism Periodic inspection and maintenance provided by a Varec service contract can prevent problems from occurring Periodic cleaning lubrication and replacement of worn parts stops trouble be
24. and counter remove the counter cover assembly as shown and described in this section Caution Be careful not to pull up and disengage or drop the pinion gear 24 If the pinion gear is disengaged it may be necessary to disassemble and reassemble the counter mechanism to properly calibrate the gauge If this becomes necessary refer to Counter Wheel Assembly section 3 4 in the Service Manual Figure 3 23 2500 ATG Counter Cover and Assembly Parts Note Reversible dials English gaugeheads are shipped with a dial indicating in feet inches and 1 16 inch The backside of the dial is marked to indicate 1 10 ft x 1 100 foot The user can reverse the dial to suit 1 Remove the counter assembly cover 2 Rotate dial plate 7 and gear 5 until the dial plate and counters display all zeros 3 Loosen dial plate screws 40 until the dial plate 7 and gear 5 rotate freely and independently of the hub assembly 4 Check that the float is at zero level with the tape taut 5 If calibration is required proceed to the next section 6 Tighten the dial plate screws 40 being careful to not overtighten them Varec Inc 41 Installation Automatic Tank Gauge 3 19 Calibrate the Counter Note Caution Note Note These instructions apply to systems that use a hollow shell welded float that is 14 5 inches 368 mm in diameter by 4 0 inches 102 mm deep Calibration is based upon the standard specif
25. cable combination anchors and guide wires as shown in the following table Table 8 9 Additional Items Recommended for Tank Overhaul Item Part No Description EE B7650 606 Tape Imperial Length 136 316 SS for a tank 60 ft high B7650 306 Tape Imperial Length 80 316 SS for a tank 32 ft high B9736 606 Tape Metric Length 41 25 m 316 SS for a tank 18 29 m high B9736 306 Tape Metric Length 24 38 m 316 SS for a tank 9 75 m high FF B7678 606 Tape and Cable 3 32 Combination Imperial Length 133 for a tank 60 ft high B7678 306 Tape and Cable 3 32 Combination Imperial Length 73 for a tank 30 ft high B13982 606 Tape and Cable 3 32 Combination Metric length 44 5 m for a tank 18 m high B7678 106 Tape and Cable 3 32 Combination Imperial Length 73 for a tank 30 ft high B13982 606 Tape and Cable 3 32 Combination Metric Length 22 2 m for a tank 9 m high GG BM5200 Top Anchor welded Steel BM5088 Top Anchor welded 316 SS BM3646 Top Anchor 1502 Steel BM3647 Top Anchor 300 Steel HH B10543 306 Guide Wire Tank Height 32 ft B10543 606 Guide Wire Tank Height 60 ft 82 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits Assembly includes other items see parts list Note Use items 44 and 45 as required 38 Tape Clamp Assembly EE or FF
26. conduit entry and elbow from the top of the stilling well and lay it on the tank roof At the elbow unroll one or two turns of the perforated tape and start to feed it into the conduit so that it appears at the bottom of the flange If your installation is a roof reading application with the gaugehead installed on the conduit feed the tape through the back of the gaugehead first Cut a 6 inch 152 mm piece of tape from the end that will be inside of the tank Form a U with this piece of tape so there is no hole in the bottom portion of the U Do not kink Form a U at the end of the perforated tape Form it to match the U piece previously formed Do not kink Install the gauge tape and U piece to the tape connector with the tape clamps and screws provided Figure 3 18 on page 31 Make certain that the tape is not kinked or twisted Connect the grounding cable A to the tape connector point B Attach the tape connector to the float Connect the grounding cable A to the float point C Lower the float down the stilling well so that is rests at the bottom of the tank well lowest measuring point Make certain that the tape is not kinked or twisted Replace the flange onto the stilling well and bolt down 34 Installation and Operations Manual 2500 ATG Installation 3 15 Feeding the Tape to a Gaugehead Located at Grade Level Note Ensure you have completed all previous steps from your installation c
27. damage to equipment which can cause injury to personnel may result if this precaution is not followed 4 1 4 Disassembly Perform the following steps to prepare the gaugehead for installation of the negator motor cassette For part number reference refer to Figure 8 4 on page 75 1 Note and record gauge level reading 2 Vent all pressure from gaugehead 3 If the gauge is oil filled drain the oil Warning If the negator motor is broken the broken pieces can cause injury Whenever the back cover of the gaugehead is removed stand away as the last bolt is removed Wear gloves and safety glasses 4 Remove 16 back cover bolts 38 and back cover 17 with any auxiliary equipment attached 5 Attach the original installation crank 59 provided with the gauge to the tape stor age sheave Warning The rapid action of the spring could result in the crank spinning and striking the operator or damaging equipment Use a firm grasp on the crank Tighten thumbscrew before releasing grip 6 Remove the outboard sheave elbow cover 7 Turn the installation crank clockwise to unwind the tape from the storage sheave Caution Be careful to insure that the tape does not kink and that it remains clean 8 While unwinding the tape in the gaugehead withdraw the tape at the outboard sheave elbow 9 When all tape is removed from the storage sheave turn the installation crank slowly counter clockwise to wind the negator spring motor onto the mo
28. female end on the lower tape entry point on the gaugehead and install the male end on the conduit Use pipe thread compound to install the coupler parts 3 Apply pipe thread compound and attach the gaugehead to the exterior vertical pipe Position it for convenient reading If not using the cam coupling connectors apply pipe thread compound to the conduit threads e If using the cam coupling connectors engage the ends of the coupling hold the gaugehead in place and lift the cam handles to lock it in place Varec Inc 29 Installation Automatic Tank Gauge 3 10 Float installation on an Out of Service Tank Note Be sure to read Chapter 2 before proceeding with this installation Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding 3 10 1 Cone Roof Tank 1 From inside the tank tilt the float on edge and slip the guide cables through the loops Set the float on the tank bottom with the tape connection up 3 10 2 Floating Pan with Floatwell Note The float s guidewires should be removed cut off as it is possible for these to get caught on the sides of the floatwell 1 Restthe float at the bottom of the tank in the float well lowest measuring point 30 Installation and Operations Manual 2500 ATG Installation 3 11 Connecting the Tape to the Float Note Be sure to read Chapter 2 before proceeding with this installation Ensure
29. handle 6 Atthe gaugehead put the first hole in the tape on a pin of the sprocket close to the tape guide 7 Rotate the sprocket clockwise to pull the tape through the guide 8 Pull the tape around the storage sheave 9 Fasten the 4th hole in the tape to the tape storage sheave on the sheave pin 10 Turn the storage sheave counter clockwise to wind up all excess tape 11 Reinstall the Negator Cassette with crank assembly into gaugehead Reinstall the two socket head screws Grasp the installation crank firmly and unlock it from the case Allow the handle to rotate to remove any additional tape slack 12 Check the tape path between the float and the gaugehead to be sure that it is not kinked or twisted Caution Do not attempt to hand crank the float above through a floating roof Hand cranking the tape beyond this point on a floating roof installation can damage and snap the tape 3 16 3 With a Hand Crank Gaugehead Caution Do not disengage the hand crank while the float is off the bottom of the empty tank or above the surface of a product A free fall may damage the float or the gauge Make certain that the hand crank is disengaged when the float is returned to the tank bottom or to the surface of the product Damage to the gauge and inaccurate measurements may result Caution Do not continue to turn the hand crank after the float reaches the top of the tank the bottom of the tank or the product level Caution Do not use the
30. make certain that this measurement is accurate because the accuracy of the automatic gauge depends upon it Refer to appropriate tank configuration to reset the gauge then use the hand gauge measurement to set the current product level Note To fill the counter assembly side of the gaugehead with oil it is necessary to change the bottom NPT condensate drain plug Replace it with a solid 1 4 NPT plug or reverse the top solid plug with the bottom plug Fill the hole in the condensate drain plug with RTV 737 sealant Varec nc 57 In Service Installation Procedures Automatic Tank Gauge 58 Installation and Operations Manual 2500 ATG Operation 5 Operation Caution Do not release the checker knob and allow the springs to return the mechanism Over time the springs will break and jam the gauge Caution Do not turn the operation checker knob on systems that have no float and that are directly connected to a floating roof 1 For non crank gaugeheads use the operation checker knob to check gauge oper ation Turn it clockwise one quarter turn while observing the display Caution For hand crank gaugeheads do not disengage the crank while the float is above the surface of the liquid Do not allow the float to free fall Damage to the system may result 2 For hand crank gaugeheads use the crank to check gauge operation refer to the initial operation paragraphs above If the float is not on the s
31. on the tape wind the excess tape counter clockwise around the storage sheave until all slack is removed 11 Check the tape path between the float and the gaugehead to be sure that it is not kinked or twisted Note If you are installing a hand crank type gaugehead proceed now to section 3 16 3 step 4 Varec In 37 Installation Automatic Tank Gauge 3 16 2 With a Negator Cassette If you have a 2500 ATG with Negator Cassette follow the procedure in this section to install the gauge tape and load the negator cassette on the gaugehead 1 Install the furnished crank assembly and lock it into the case keyhole slot using the spring loaded screw 2 Remove the two socket head screws attaching the Negator Cassette to the storage sheave 3 Remove the Negator Cassette from the gaugehead by pulling it straight out Warning Do not overwind negator motor Winding motor greater than the indicated number of turns may cause the motor to dislodge and uncoil from its pulley causing damage to equipment and injury to personnel Warning Use both hands for a firm grasp on the crank while winding motor Tighten thumbscrew before releasing grip The rapid unwinding of the spring could result in the crank spinning and striking the operator 4 Grasp the crank assembly handle and unlock it from the Negator Cassette Wind the motor clockwise 45 turns 5 Lockthe crank assembly into the case keyhole slot before releasing your grip on the
32. the systems Contact Field Service a Varec representative or Product Marketing for more information 1 2 Getting Acquainted with the 2500 Automatic Tank Gauge Systems The 2500 series of Automatic Tank Gauges ATG are float and tape operated instruments designed to provide continuous liquid level measurement in bulk storage applications The gauge can be installed on the tank roof or at the tank side at grade which would facilitate ground level reading by the operator and is available with a wide variety of accessories for virtually every tank gauging application The level measurement is displayed using a dial and counter built into the ie gaugehead If electronic transmission of level data or temperature measurement integration is required in the control room the gauge can be fitted with an optional tank gauging transmitter Figure 1 1 Right Typical 2500 ATG Installation 2500 Automatic Tank Gauge and Transmitter Tank Gauge Interface e g RTU8130 Inventory Management System e g FuelsManager Varec Inc 1 Introduction Automatic Tank Gauge 1 2 2 1 2 1 Tank Gauge Operation The 2500 ATG uses a large stainless steel float attached to a stainless steel perforated tape to detect the liquid level The float follows the liquid level In some systems the roof of the tank serves as the float Varec does not recommend this as it rises and falls due to the tension provided by a powerful negator spring or cartridge
33. to a floating pan Use a covered floatwell for the best measurement accuracy Step Description Complete Section 3 5 Correct Float Positioning for an External Floating Pan Installation on page 25 Section 3 7 Installing Support Brackets amp Pipework on page 27 Section 3 8 Installing a Gaugehead at Grade Level on page 28 Section 3 13 Connecting the Cable to a Floating Pan on page 33 us BR wy N Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 Section 3 16 Install Tape in the Gaugehead on page 36 Section 3 18 Reset the Counter on page 41 Section 3 19 Calibrate the Counter on page 42 oO o n oa Section 3 20 Initial Lubrication on page 43 10 Section 3 21 Install a Transmitter and Replace all Covers on page 44 11 Section 3 22 Initial Operation on page 45 16 Installation and Operations Manual 2500 ATG General Preparation 2 4 9 Interface Service Order Code T51 T52 T53 T54 Installation parts supplied include 90 Elbow assembly x2 amp conduit connector kit Gauge U bolt kit Guidewire bottom anchor Guidewires Support bracket x6 Gaugehead and tape Interface float Guidewire top anchors x2 AJ Tape connectors Conduit connector kit 2 4 9 1 T Installation Checklist When installing a 2500 ATG system on a cone roof tank
34. to accommodate the coupling for the 1 5 inch pipe 5 Screw the drop pipe coupling into the vertical pipe nipple This will aid in positioning the coupling while welding 6 Check the pitch of the roof Hold the coupling plumb while welding it into the hole in the roof Note Failure to place the coupling and pipe in a true vertical position may affect the accuracy of the gauge 7 After the coupling and pipe are checked to make certain that they are plumb unscrew the pipe from the coupling Note Make sure that the interior of all pipes are clean and corrosion free 8 Sealthe threads with a pipe thread compound and reconnect the pipe to the coupling Varec Inc 23 Installation Automatic Tank Gauge 3 4 Tank Roof Entry Stilling Well Note To facilitate inspection and service of the gauge system locate the well where gauge piping will pass over the top of the tank shell close to a stairway platform 1 Inauser supplied flange that is suitable to connect to the stilling well on your tank provide a center hole for the conduit to screw into the flange 2 Connect the conduit to the flange Note Failure to place the coupling and pipe in a true vertical position may affect the accuracy of the gauge 3 After the coupling and pipe are checked to make certain that they are plumb unscrew the pipe from the flange Note Make sure that the interior of all pipes are clean and corrosion free 4 Seal the threads wit
35. 0 0c e eee eee 67 Maintenance Routines 0000055 69 Operation Check sis us mE Oud ead ews a sable baa E Qe os 70 vi Installation and Operations Manual 2500 ATG 1 2 eak COCK wise ace ties hen te ass tak eria eo Nien ante ie A aie Biagio PU en aaa dx 70 7 3 Sediment Check 000 ccc tees 70 7 4 Deformation Check 0000 c cette eee 70 7 5 Calibration Check 0 0 00 tee 70 7 6 Float and Guidewires Check 0 0 0 0 cee eee ee 70 Tr L bricatiOri icc hol eter eee ie we nel ed ee een 71 7 7 1 Other lubricants recommended for general service 71 7 7 2 Other lubricants for service below 25 F 4 C 0 0 0c eee eee 71 7 8 Oil filled Gauge Check 0 0 0 0 000 cee 71 7 9 Corrosion check 71 7 10 Basic maintenance 0 0 00 nes 72 7 11 Extended maintenance 0 0 72 7 12 Overhaul maintenance 0 00 c cee 72 7 18 General Inspection 0 00 es 72 8 Spare Parts and Maintenance Kits 73 8 1 Gaugehead Spare Parts 0 0 0 teens 73 8 2 Basic Maintenance Kit liliis 76 8 3 Extended Maintenance Kit lille 78 8 4 Overhaul Refurbishing Kit llli ees 81 8 4 1 Additional tems occa a ee hee eR ROS RR ee n 82 8 5 Shoulder Bushing Retrofit Kit 00 0c cee 84 8 6 Negator Cassette and Negator Cassette Kit 000005 85 8 7 Gaug
36. 0 165 ft meters x 1 1000 M 0 0 0 5 4 inches Caution Do not attempt to hand crank the float above through a floating roof Hand cranking the tape beyond this point on a floating roof installation can damage and snap the tape 4 Observethe operation of the counter drums and dial while slowly cranking the float to the top of the tank and then lowering it to the bottom The counter drums and dial should rotate freely and return to the calibrated indication when the float touche s the tank bottom Figure 3 24 Dial Plate Adjustments 42 Installation and Operations Manual 2500 ATG Installation 3 20 Initial Lubrication Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Caution Gauges measuring caustic liquids require that the gaugehead be oil filled Failure to protect the gaugehead with oil may result in damage Note Refer to Section 7 7 Lubrication on page 71 for recommended oil 1 Apply a light oil to the elbow sheave 2 Ifthe gaugehead is not going to be filled with oil apply a light oil to the tape sprocket and storage sheave 3 Ifthe gaugehead is to be filled with oil reassemble the gaugehead then fill with oil For most service Varec recommends filling the gaugehead with oil to reduce wear and prolong the service life
37. 02 MOQ 3 9 eeus uonejejsu jooy Buryeoj4 ejduiex3 VV 440 33 G o 6 88 6 2500 ATG Extended Maintenance Kit parts Figure 8 Installation and Operations Manual 80 2500 ATG Spare Parts and Maintenance Kits 8 4 Overhaul Refurbishing Kit The Refurbish Overhaul Kit provides all the parts required for overhaul maintenance on the 2500 ATG Depending on your selection you will receive the metric or imperial parts required listed in Table 8 8 Table 8 7 Overhaul Refurbish Maintenance Kits Part No Description 13 08770 Overhaul Refurbishing Maintenance Kit Imperial 13 08771 Overhaul Refurbishing Kit Metric Table 8 8 Overhaul Refurbish Maintenance Kit Part Numbers Item Part No Description Quantity in kit B4396 071 Back Cover Gasket 02 04490 071 Back Cover Gasket 1 B7415 093 Teflon Washer 1 B8235 040 Imperial Dial Gear 1 Imperial kit only 5m B8327 040 Metric Dial Gear 1 Metric kit only 6 B7720 071 Counter Cover Gasket 1 7 B8218 001 Imperial Dial Fractional or Decimal 1 Imperial kit only 7m B8325 001 Metric Dial 1 Metric kit only 9 B8234 001 Dial Retainer 12 B10221 093 Seal 14 BA14055 Gauge Check
38. 2 Tape or cable off elbow pulley Remove elbow covers Yes Reseat and lubricate the gauge No Go to 3 3 Elbow pulley shaft or bushing Yes is worn or Repair or replace No Go to 4 4 Tape conduit dirty Yes Remove and clean No Go to 5 5 Guide cables loose kinked or Yes broken Tighten repair or replace No Go to 6 6 Worn Teflon bushings or Yes Refurbish gauge replace Teflon bushings or bearings Special tools may be required 90 Installation and Operations Manual 2500 ATG Specifications and Reference Data 10 Specifications and Reference Data 10 1 Device Designation Nameplate 2500 Automatic Tank Gauge Model No C 1725 9 16 FM 06 ATEX 0009 Serial No Ambient Temperature Limits 40 C TO 85 C Date Of Mfr Reference the Installation and Operations Manual for Details ec C Made in USA Gaugehead Type B a EX B7817 REV S f Varec Inc An SAIC Company n 5834 Peachtree Corners East Norcross Atlanta Georgia 30092 USA x Figure 10 11 Nameplate for the 2500 ATG 10 2 CE Marks 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 50014 Electrical apparatus for potentially explosive
39. 3 5 mm diameter hole in the cover to carry the tape drop pipe 4 Cut two 1 75 inch 44 5 mm diameter holes in the cover to carry the top guide cable anchors Ui Disassemble the inspection cover and gasket from the frame 6 Weld the inspection cover frame to the manhole cover 7 Weld the guide cable anchor nipples and the tape drop pipe coupling in place Make certain that they are vertical and correctly centered 8 Carry the modified cover assembly back to the tank site Orient the modified man hole cover as shown and reinstall 9 Refer to the appropriate tank configuration figure to check the tank configuration and install the tape piping and gaugehead 4 3 2 Manhole Cover This section gives instructions to install 226 20 inch and 24 Inch Manhole Covers with API Drilling Install 226 20 inch Part Number BM3443 and 24 inch Part Number BM3607 manhole covers with API drilling 1 Remove the existing manhole cover 2 Separate the 226 cover in two by removing the bolts 3 Install the cover half with the pipe coupling to the top of the tank 4 Refer to the appropriate tank configuration figure to check the tank configuration and install the tape piping and gaugehead DETAIL C Existing Manhole Cover Modifications o 25 14 Plas 00 254 6 j 2 75 70 Se s o o olo Assembled 19 75 502 o 6 00 152 Ld 19 di L 4 8 DETAIL B 1 75 a
40. 41 Section 3 19 Calibrate the Counter on page 42 Oloo NIAJ BR Ww N Section 3 20 Initial Lubrication on page 43 10 Section 3 21 Install a Transmitter and Replace all Covers on page 44 11 Section 3 22 Initial Operation on page 45 Varec Inc 13 General Preparation Automatic Tank Gauge 2 4 6 Stilling Well Service Cone Roof Tank 6 Diameter Float Order Code T55 T56 Installation parts supplied include 90 Elbow assembly x2 amp conduit connector kit Gauge U bolt kit Guidewire anchor weight Guidewires Support bracket x6 Gaugehead and tape Float Guidewire top anchors x2 Tape connectors Conduit connector kit 2 4 6 1 Installation Checklist When installing a 2500 ATG system on a Stilling Well Service Cone Roof Tank 6 Diameter Float complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Description Complete 1 Section 3 4 Tank Roof Entry Stilling Well on page 24 Section 3 7 Installing Support Brackets amp Pipework on page 27 Section 3 8 Installing a Gaugehead at Grade Level on page 28 Section 3 10 Float installation on an Out of Service Tank on page 30 2 3 4 5 Section 3 14 Connecting the Tape to an Interface Float in a 6 Stilling Well on
41. 43 That section gives instructions to reset and calibrate the counter 68 Installation and Operations Manual 2500 ATG Maintenance Routines 7 Maintenance Routines Varec recommends a regular schedule of maintenance for the 2500 Automatic Tank Gauge ATG outlined in the table below Actual frequency of inspections and maintenance may vary depending on the specific environmental conditions and operation at your site even from tank to tank Study your installations and plan a routine of inspection and maintenance that best suits your site s individual needs Regular maintenance lengthens the service life and assures more accurate gauge readings Varec can provide spare parts maintenance kits and preventive maintenance advice training or warranties Please consult your product Installation and Operations Manual or a representative for more information Warning Hazardous environment Observe appropriate safety precautions in flammable or hazardous liquid storage areas Do not enter a tank that has contained hydrocarbons vapors or toxic materials until a gas free environment is certified Carry breathing equipment when entering a tank where oxygen may be depleted with carbon dioxide nitrogen or other gases Warning Possible Electrostatic Discharge Hazard Worker activity and worker clothing may accumulate electrostatic charges on the body of a worker The mechanical connections between guide cables float tape and gaug
42. BB Sheave Elbow Cover Gasket Example Cone Roof Installation BB Top Guidewire Anchor GG 2500 ATG Overhaul Maintenance Kit Parts and Additional Items Varec Inc 83 Spare Parts and Maintenance Kits Automatic Tank Gauge 8 5 Shoulder Bushing Retrofit Kit The Shoulder Bushing Retrofit Kit provides the parts required to replace the shoulder bushings on the 2500 ATG Table 8 10 Shoulder Busing Kit and Individual Parts Part No Description 13 09794 00 Shoulder Bushing Retrofit Kit Item Part Description QTY 23 P10 2 Retaining Ring 4 44 P31 1 Washer 2 45 P31 13 Shim Washer 6 55 02 09598 Shoulder Bushing 2 56 B14872 101 Motor Top Plate 1 na SRMOOI Service Manual 1 Note Use items 44 and 45 as required Figure 8 7 Shoulder Bushing Retrofit Kit Parts 84 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits 8 6 Negator Cassette and Negator Cassette Kit The Negator Cassette Kit item 68 provides the parts required to convert a 2500 ATG fitted with a negator motor to a gaugehead with a negator cassette Table 8 11 Negator Cassette Kit and individual Parts Item Part Description QTY 50 06 10368 Negator Cassette only na 68 13 10652 Negator Cassette kit na Item Part Description
43. G read and review all Safety Precautions on page ii of the preface to this document Continuing with installation according to the instructions in this manual presumes you have reviewed these safety precautions Note Refer to Section 2 4 Identifying Your Installation Type on page 9 before proceeding Varec Inc 19 Installation Automatic Tank Gauge 3 1 Installation Schematics 1 1 2 Inch pipe and fittings 1 1 2 Inch NPTcoupling furnished by customer 7 recommended 1 vl 4 50 s 7 4 8 114 j Jd d LA laso Ss i 14 24 00 PE 610 ey Suggested uae L 368 Maximum 36 00 I S m pi 8 00 16 00 L3 l 14 50 Note Instalation hatch not shown Varec recommends installing a installation hatch 203 Layout for pipe supports spaced approximately at 10 foot 3 meter intervals 406 6 00 152 Convenient eye level ST Grade POPE TEREE V a Ui View C C Pipe support bracket detail Gaugehead Float Tape Tape Cable fastner Pipe Support Bracket Top Anchor Bottom Anchor Sheave elbow Float Guide Cable O ONAARWNA Unless otherwise noted dimensions in inches millimters All welding by customer Figure 3 8 Cone Roof Tank 1 1 2 Inch pipe and
44. IOMOO1GVAEO609 2500 Automatic Tank Gauge Mechanically operated float and tape gauges for continuous liquid level measurement in bulk storage tanks Installation Operations and Service Manual amp Varec Inc 5834 Peachtree Corners East Norcross Atlanta GA 30092 USA Tel 1 770 447 9202 Fax 1 770 662 8939 2500 ATG Copyright All rights reserved Printed in the United States of America Except as permitted under the United States Copyright Act of 1976 no part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of the Publisher Varec Inc 5834 Peachtree Corners East Norcross Atlanta GA 30092 USA Trademarks acknowledged Varec Inc recognizes all other trademarks Trademarks of other products mentioned in this document are held by the companies producing them Delrin is a registered trademark of E du Pont de Nemours Co Inc Wilmington DL Dow Corning RTV 737 is a registered trademark of Dow Corning Inc Midland MI Loctite is a registered trademark of Loctite Corp Newington CT Teflon is a registered trademark of E I du Pont de Nemours Co Inc Wilmington DL Viton is a registered trademark of E I Du Pont de Nemours Co Inc Wilmington DL Varec is a registered trademark of Varec Inc Copyright 2008 Sier
45. Loosen the motor spring screw Fig 3 1 item 8 and detach motor spring Remove retaining ring 23 washer 44 and shim washers 45 from motor shaft Remove motor storage sheave assembly 48 as a unit Remove retaining ring 23 washer 44 and shim washers 45 from tape storage sheave shaft Remove tape storage sheave assembly as a unit Caution Do not remove the sheave shafts The sheave shafts are pressed into place and 19 20 21 22 23 24 25 26 27 28 29 retained with a permanent adhesive compound Loosen sprocket sheave set screw 28 and remove sprocket sheave assembly 18 Teflon washer 4 shim washers 45 and washer 37 Remove tape keeper assembly which includes screw 27 post 16 and spring 25 Remove six counter cover screws 39 counter cover assembly 19 and counter cover gasket 6 Remove three dial retainer screws 40 dial retainer 9 and dial 7 Remove the dial gear 5 Remove the pinion gear 24 Remove three counter assembly mounting screws 43 and counter assembly 21 Remove counter shaft assembly 11 and any shim washers if needed 45 Loosen gauge check knob set screw 42 Remove gauge check knob 13 grip ring 29 and shim washer 33 Remove gauge check assembly 14 shim washer 33 and gauge check spring 15 Remove Viton o ring 22 on outside of gauge check boss Caution Do not remove the Teflon o ring before assessing the need to re
46. Note To fill the counter assembly side of the gaugehead with oil itis necessary to change the bottom NPT condensate drain plug Replace it with a solid 1 4 NPT plug or reverse the solid top plug with the bottom plug Fill the hole in the condensate drain plug with RTV 737 sealant 4 lf your installation requires oil seals on the tape run conduit elbows refer to Section 4 2 Oil Seal Installation on page 52 Varec Inc 43 Installation Automatic Tank Gauge 3 21 Install a Transmitter and Replace all Covers Note Be sure to read Chapter 2 before proceeding with this installation Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Caution Donotstore the installation crank and thumbscrew in the gaugehead but keep them at a storage area for future use Caution Do not over torque the back cover bolts 1 2 Remove the installation crank and thumbscrew When a transmitter or other auxiliary equipment is to be installed ensure the equipment hole size and bolt pattern matches the 2500 ATG Remove and discard the cap and red fiber washers from the back cover Each transmitter s slotted coupling should properly engage the sprocket sheave auxiliary drive pin Use the cap screws to attach the transmitter to the back cover Refer to the transmitter documentation for detailed installation configuration and operation
47. QTY 4 B7415 093 Teflon Washer Not shown as used on older models 2 23 P10 2 Retaining Ring 5 16 SS 44 P31 1 Washer 9 16X21 64X1 16 SS 45 P31 13 Shim washer 562X 316 313X 005SS 6 49 P031 11 1807 HSCS 1 4 20X1 1 4 2 50 06 10368 Negator Cassette 51 06 10364 Tape Storage Sheave Assembly Cassette 1 52 06 10490 Handle Crank 1 na SRM001 Service Manual 1 Standard Gaugehead The Negator Cassette Conversion Kit replaces all the parts highlighted from a standard gaugehead Note Use items 44 and 45 as required Negator Cassette Gaugehead 52 Figure 8 8 Negator Cassette Conversion Kit parts Item 68 Varec Inc 85 Spare Parts and Maintenance Kits Automatic Tank Gauge 8 7 Gaugehead Conduit Connector and Kit The Gaugehead Conduit Connection Kit allows you to easily remove the gaugehead to perform repair and maintenance The male end of the cam lock coupling threads onto the gaugehead The female end of the coupling threads onto the conduit varec recommends installing the connectors to the conduit and gaugehead with adhesive compound Figure 8 9 Gaugehead Conduit Connector and Kit Table 8 12 Gaugehead Conduit Connection Kit and Individual Parts Item Part Description Qty 69 13 10100 Gaugehead Conduit Connection Kit contains 1 parts 67 amp 68 Item Part Description Qty 67 P30 100 Gaugehead Connector male end 1
48. ake certain that it is plumb Thread the cable through the guidewire Attach the cable to the float with the furnished fastener and ground cable Figure 3 18 Note There should be at least 12 clearance between the top of the float at the liquid level and the top of the float well Put the bottom of the float on the bottom of the tank in the float well Make certain that the tape tape cable is not kinked or twisted Figure 3 20 Cable length calculation 9 Cut the cable to the correct length to ensure the splice between the tape and cable does not run over an elbow pulley or is drawn into the gaugehead Consider Figure 3 20 and apply it to your particular Ensure you have completed all previous steps from your installation checklist from On internal or external floating pan installations one end of the tape is connected Tape Y l1 i eh At least 12 Product Level Minimum Roof Level installation or call Varec Help desk with questions e A B C D E Correct Cable Length uum Splice position x is optimum for empty or out of service tanks Maximum fill and minimum read positions should never be greater than the F dimension 32 Installation and Operations Manual 2500 ATG In
49. amage to the float or tank may result Note Be sure to remove the installation crank when installation is complete Do not store the crank or the thumbscrew in the gaugehead Put them in a storage area for safe keeping and future use With a Negator Spring Motor 1 If you have a Standard 2500 ATG with a Negator Spring Motor follow the procedure in this section to install the gauge tape and load the negator motor on the gauge head 2 Attach the furnished installation crank and thumbscrew to the tape storage sheave 3 Wind the storage sheave clockwise the number of turns indicated in Table 3 2 and then securely tighten the thumbscrew Table 3 2 Turns to Wind Negator Motor Motor Sheave Part No Gaugehead Motor Normal Application Turns w 2500 ATG BA7762 Standard 0 60 0 18m tank range 45 BA17725 Extra Strong 0 60 0 18m tank range 47 BA17087 Extra Long 0 96 0 29m tank range 63 4 f you have a hand crank type gaugehead ensure that the motor is wound and the ratchet pawl is at mid position engaged 5 Atthe gaugehead put the first hole in the tape on a pin of the sprocket close to the tape guide 6 Rotate the sprocket clockwise to pull the tape through the guide 7 Pull the tape around the storage sheave 8 Fasten the 4th hole in the tape to the tape storage sheave on the sheave pin 9 Hold the installation crank firmly and loosen the thumbscrew 10 While keeping tension
50. ance Kit Metric Table 8 5 Extended Maintenance Kit Parts Item Part No Description Quantity in kit B4396 071 Back Cover Gasket 02 04490 071 Back Cover Gasket 4 B7415 093 Teflon Washer 1 5 B8235 040 Imperial Dial Gear Imperial kit only 5m B8327 040 Metric Dial Gear Metric kit only 6 B7720 071 Counter Cover Gasket 7 B8218 001 Imperial Dial Fractional or Decimal Imperial kit only 7m B8325 001 Metric Dial Metric kit only 9 B8234 001 Dial Retainer 1 12 B10221 093 Seal 1 14 BA14055 Gauge Check Assembly 1 15 B7796 005 Spring 1 16 B6547 005 Tape Keeper Post 1 21 BM18849 100 Imperial Counter Assembly Imperial kit only 21m BM18850 100 Metric Counter Assembly Metric kit only 22 P14 146 O Ring 23 P10 2 RETAINING RING 5 16 SS 1 24 P25 16 Pinion Gear 1 25 B7300 005 Tape Keeper Spring 1 26 P14 23 O Ring Seal 1 27 P31 669 Binding Head Mach Screw 1 29 P10 29 Grip Ring 1 31 P13 20 Bushing 1 33 02 08543 Washer 2 37 B4847 005 Washer 1 39 P031 07 1679 Rd Head Mach Screw 6 40 P031 01 1719 Binding Head Mach Screw 3 42 P31 612 Hex Socket Set Screw Cup Pt 1 43 P031 08 1720 Self Tap Screw 3 44 P31 1 Washer 45 P31 13 Shim Washer 18 48 BA7762 Negator Motor Ass y includes items 55x2 amp 56 55 02 09598 Shoulder Bushing 2 57 P31 671 Screw 58 P31 692 Screw 59 BM3784 Original handle Crank Not Shown 1 AA BM5478 600 Tape Clamp Assembly 1 BB A371 071 Cover Gas
51. ard Varec Inc 47 In Service Installation Procedures Automatic Tank Gauge Inspection Cover For existng 20 inch and larger manhole covers Piping and fittings See details B amp C furnished by customer Existing standard roof manhole with gasket amp mounting hardware 36 00 914 Maximum 9 229 16 00 406 Minimum Space approximate Guided float IN Pipe support yo brackets for ie Typical Hex head welding to cap screw Float guide customer support R cable structure Space brackets approximately at 10 foot 3 meter Float guide intervals cables Cable clamps Anchor weight 17 00 DETAIL A 432 e In service anchor weight ordered separately Support structure SUS set in concrete Figure 4 26 Typical In Service Tank Installation with Manhole Inspection Hatch and Independent Pipe Support Structure Detail A shows in service bottom anchor 48 Installation and Operations Manual 2500 ATG In Service Installation Procedures 4 1 Negator Cassette Installation Varec s negator cassette is a fully enclosed design to safely contain a damaged or failed negator motor It will extend negator motor life by keeping pipe scale and debris off the negator motor The cassette provides quick and easy change out of any future negator motor failures Caution Damage to equipment may result if this precaution is disregarded Warning Direct injury to personnel or
52. ate service cone roof tank Stilling well service cone roof tank N250011 Complete product designation 11 8 Aluminum Gaugehead Metric Configuration Negator Cassette 10 Tank Type T11 Standard service cone roof tank T12 Standard service cone roof tank with pan amp floatwell T13 Standard service floating roof tank amp floatwell T14 Standard service tank top mounting T15 Standard service bolted tank T16 Standard service floating roof tank no floatwell T17 Standard service cone roof tank amp pan no floatwell T42 Moderate service cone roof tank T56 Stilling well service cone roof tank N250013 Complete product designation 96 Installation and Operations Manual 2500 ATG NOTES Varec Inc 97 2500 ATG IOMO01GVAE0409 Y our official representative Varec Inc 5834 Peachtree Corners East Norcross Atlanta GA 30092 USA Tel 1 770 447 9202 Fax 1 770 662 8939 Varec Inc An SAIC Company All Rights Reserved This document is for information purposes only Varec Inc makes no warranties express or implied in this summary The names of actual companies and products mentioned herein may be the trademarks of their respective owners
53. ation go to section 3 16 3 Varec Inc 35 Installation Automatic Tank Gauge 3 16 Install Tape in the Gaugehead Caution Do not release crank handle 7 when negator spring motor is being loaded and thumbscrew lock is removed Item Description Sprocket Sheave Tape Storage Sheave ThumbScrew Lock Tape Keeper Motor Storage Sheave Negator Spring Motor Removable Installation Crank Negator Spring Motor Screw Tape Sheave Pinor Screw Standard Gaugehead with negator spring motor OONODARWNH Tape entry for Top Mounted Gauge Tape entry for Side Mounted Gauge Standard Gaugehead Negator Cassette Gaugehead with negator spring motor shown with negator cassette removed for tape installation Figure 3 22 Tape Routing 36 Installation and Operations Manual 2500 ATG Installation 3 16 1 Warning Do not overwind negator motor Winding motor greater than the indicated number of turns may cause the motor to dislodge and uncoil from its pulley causing damage to equipment and injury to personnel Warning Use both hands for a firm grasp on the crank while winding motor Tighten thumbscrew before releasing grip The rapid unwinding of the spring could result in the crank spinning and striking the operator Caution Do not allow the float to fall back to the floor of the tank D
54. atmospheres General requirements 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 10 3 2500 ATG Gaugehead Description Material Gaugehead Aluminium Counter housing amp cover Aluminium Sprocket Motor Storage and Tape storage sheaves Cast aluminum Negator spring Perforated tape and Sprocket Pins Type 301 stainless steel Type 316 stainless steel Type 303 stainless steel Bearings Stainless steel Varec Inc 91 Specifications and Reference Data Automatic Tank Gauge 10 4 2500 ATG Product Dimensions 3 0 76 mm are 5 8 E 8 5 1 2 NPT 5 16 18x1 15 mm 147 mm 216 mm I Po 91 28 32 mm gt 5 4 5 16 18x1 9 137 mm E 13 6 345 mm ED EG TT LO T Y LO y tf 3 8 TE 1 1 2 NPT be 22 TS 56 mm 140 mm 8 7 221 mm 10 5 Floats Part Material Net Weight Size BM9074 000 316 S S 8 8 Ib 4 kg 17 432 mm Flat BM12339 000 Carp 20 10 7 Ib 4 9 kg 17 432 mm Flat BM12338 000 Monel 10 5 Ib 4 8 kg 17 432 mm Flat BM12411 316 SS 11 Ib 8 203 mm Multi sphere BM17777 006 316 SS Depends on specific gravity 8 203 mm S
55. ck Cover Gasket 02 04490 071 Back Cover Gasket B7415 093 Teflon Washer 1 B8235 040 Imperial Dial Gear 1 Imperial kit only 5m B8327 040 Metric Dial Gear 1 Metric kit only 6 B7720 071 Counter Cover Gasket 1 7 B8218 001 Imperial Dial Fractional or Decimal 1 Imperial kit only 7m B8325 001 Metric Dial 1 Metric kit only 16 B6547 005 Tape Keeper Post 21 BM18849 100 Imperial Counter Assembly 1 Imperial kit only 21m BM18850 100 Metric Counter Assembly 1 Metric kit only 23 P10 2 Retaining Ring 6 24 P25 16 Pinion Gear 25 B7300 005 Tape Keeper Spring 27 P31 669 Binding Head Mach Screw 40 P031 01 1719 Binding Head Mach Screw 3 43 P031 08 1720 Self Tap Screw 3 44 P31 1 Washer 6 45 P31 13 Shim Washer 16 55 02 09598 Shoulder Bushing 4 56 B14872 101 Motor Top Plate na SRMOO1 Service Manual Varec nc 77 Spare Parts and Maintenance Kits Automatic Tank Gauge 8 3 Extended Maintenance Kit The Extended Maintenance Kit provides all the parts required for extended maintenance on the 2500 ATG Gaugehead Depending on your selection you will receive the metric or imperial parts required listed in Table 8 5 Table 8 4 Extended Maintenance Kits Part Numbers Part No Description 13 08768 Extended Maintenance Kit Imperial 13 08769 2 Extended Mainten
56. ckets 2 If using the gaugehead conduit connectors install the couplers Install female end on the gaugehead and install the male end on the conduit Use pipe thread compound to install the coupler parts 3 Apply pipe thread compound and attach the gaugehead to the exterior vertical pipe Position it for convenient reading f not using the cam coupling connectors apply pipe thread compound to the conduit threads e If using the cam coupling connectors engage the ends of the coupling hold the gaugehead in place and lift the cam handles to lock it in place Welded Bolted p l Tank Wall m Tank Wall I 1 1 2 Inch NPT union and Conduit Connection Kit close nipple previously furnished by allows easy gaugehead customer installation Figure 3 16 Conduit Connection and Tank Side Support Bracket Details 28 Installation and Operations Manual 2500 ATG Installation 3 9 Installing a Roof Reading Gaugehead Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Warning When removing the gaugehead back cover stand to one side as the last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed 1 Remove the back cover and gasket from the gaugehead 2 If using the gaugehead conduit connectors install the couplers Install
57. d Tighten cable locking nut to secure cable in place Tighten the adjustment nut until the guide cable is tensioned by the spring Trim excess cable Use pipe thread compound and install top anchor nipples and cap Warning Whenever the back cover of the gaugehead is removed stand to one side as the 0 last bolt is removed If the negator motor spring is broken the broken pieces may cause injury when the cover is removed Remove the back cover and gasket from the gaugehead Remove the bolts covers and gaskets from the elbows Apply pipe thread compound and attach the gaugehead to the exterior vertical pipe Position it for convenient reading The weight of the gaugehead is supported by the pipe and brackets Using the box that the tape came in pull the tape out like a measuring tape This keeps the tape from becoming twisted or kinked At the elbow on the tank entry pipe unroll one or two turns of the perforated tape and start to feed it into the hor izontal pipe Caution Ifthe tape binds in the pipe during threading check the pipe for corrosion and other 1 obstructions Check the tape to make certain that it did not kink Friction in the pipe will affect accuracy and may break the tape Install the gauge tape and U piece to the tape connector with the tape clamps and screws provided Grounding Cable ES Tape Grounding Clamp p Clamp screw S 2 required 6 00 Inch
58. de 90 Elbow assembly x2 Guidewire bottom anchor Guidewires Support bracket assembly Support bracket x7 Gaugehead and tape Float Guidewire top anchors x2 Tape connectors 1 1 2 Deck flange Conduit connector kit 2 4 2 1 Installation Checklist When installing a 2500 ATG system on a bolted tank complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Description Complete 1 Section 3 3 Tank Roof Entry Internal Pan Floating Roof on page 23 Section 3 6 Installing Anchors and Guidewires on page 26 Section 3 7 Installing Support Brackets amp Pipework on page 27 Section 3 8 Installing a Gaugehead at Grade Level on page 28 Section 3 10 Float installation on an Out of Service Tank on page 30 Section 3 11 Connecting the Tape to the Float on page 31 2 3 4 5 6 7 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 Section 3 16 Install Tape in the Gaugehead on page 36 Section 3 18 Reset the Counter on page 41 10 Section 3 19 Calibrate the Counter on page 42 Section 3 20 Initial Lubrication on page 43 12 Section 3 21 Install a Transmitter and Replace all Covers on page 44 13 Section 3 22 Initial Operation on
59. document must be submitted to and approved by the agency s before public release ATEX Notified Body FM Approvals Ltd Safety Precautions Read this manual carefully and make sure you understand its contents before using this product Follow all instructions and safety guidelines presented in this manual when using this product If the user does not follow these instructions properly Varec cannot guarantee the safety of the system Note Comply with all applicable regulations codes and standards For safety precautions the user should refer to the appropriate industry or military standards Caution Electrical Hazard Read and understand static and lightning electrical protection and grounding described in API 2003 Make certain that the tank installation operation and maintenance conforms with the practice set forth therein Warning Striking the gaugehead with a metal object could cause a spark to occur When removing or replacing the gaugehead in flammable or hazardous liquid storage areas take necessary measures to protect the gaugehead from impact Warning Volatile fumes may be present Make certain that the tank is empty and not in service Ensure that the tank has been leak and pressure tested as appropriate for the liquid to be stored Observe appropriate safety precautions in flammable or hazardous liquid storage areas Do not enter a tank that has contained hydrocarbons vapors or toxic materials until a gas free enviro
60. e safety precautions The instructions to install the perforated tape in the gaugehead vary depending on the type of tape winding mechanism in your gaugehead The instructions for each of these methods follow the basic 2500 ATG system installation instructions They include e Negator Spring Motor e Negator Cassette Hand Crank This manual does not cover all possible installations Contact Varec if you need additional support or information for your installation Tools Equipment and Materials User responsibilities include provision of the following items e 1 5 inch o d conduit that carries the perforated tape Necessary mounting and support pipe and welding Drilling of any holes in the tank as needed Assembling the necessary tools and equipment at the work site Table 2 1 lists typical tools and equipment that may be needed Use a drop cloth to maintain tool equipment and installation kit cleanliness Table 2 1 User supplied typical tools and equipment tape measure long string level Pipe taps amp dies cable cutter chalk amp line vice light oil pipe cutter compass protractor Dow Corning 4 compound sheet metal shears plumb bob Electric drill amp bits Dow Corning RTV 737 hole cutters screwdrivers tank hand gauge Loctite 567 pick pliers Welding equipment Loctite 262 shovel wrenches clean drop cloth Varec nc General Preparation Automatic Tan
61. ehead Conduit Connector and Kit 0 000 e ee eae 86 8 8 Float Grounding Kit 0 000 cee tenes 86 8 9 Other Accessorie Ss sinsa s E E wae Pie bites EGA C MERGE 87 8 9 1 Gauge Calibrator Assembly llle 87 8 9 2 Condensate Reservoir 2 87 8 9 3 Shock Absorber 0 0 ia a Taat eee 87 8 9 4 Teflon Tape Wipe 2 0 ce ee 87 9 Troubleshooting sseesssess 89 9 1 Dials Do Not Respond When Gauge Check Knob is Rotated 89 9 2 Calibration Repeatability Unstable llle 90 10 Specifications and Reference Data 91 10 1 Device Designation Nameplate llis 91 10 2 CE Marks Declaration of Conformity 00000 cee eae 91 10 3 2500 ATG Gaugehead 0 ees 91 10 4 2500 ATG Product Dimensions sasaaa aaea aae 92 Varec Inc vii Automatic Tank Gauge 10 5 Floats i5 oce ern E eer itin e ae tiere t dx ber Plas ace Pen debug 92 10 6 Conduit Elbows 0 0 00 ccc tees 93 10 7 Standard Installation Kits llli 93 10 8 Gil Seals 5 eed etes a lr etu dte A pe EI a ol ete sc N de 93 10 9 Approvals sz 5st e ette er etae tate gate ded x des V aid 94 10 10 Other Specifications 0 0 0 0 eee ees 94 11 Order GOOBS crac e t E uite whore bi dert Mie 95 11 1 Aluminum Gaugehead English Configuration Negator Motor 95 11 2 Aluminum Gaugehead Metric Configurati
62. ehead provide a resistance to ground that is adequate for the safe electrical drain of electrostatic charges that may accumulate in the tank and the product Warning Electrical and hazardous vapor hazards are inherent to the work described in this manual Observe American Petroleum Institute API Recommended Practice 2003 or other appropriate industry or Military Standard The following table shows the suggested periodic maintenance and inspection routine for the 2500 ATG Each element is described in the following paragraphs Table 7 1 Suggested Periodic Maintenance Routines Routine 90 Days 6 Months 1 Year Inspect 5 Year Inspect 10 Year API 653 amp Maintain amp Maintain Overhaul Operation check X X X Leak check X X X Sediment check X X X Deformation check X X X Calibration X X Float and guide cables check X X Lubricate X Oil filled gauge check X Corrosion check X Basic Malntenance As required depending on service Extended Maintenance conditions Refurbish Overhaul X Recommended Varec Inc 69 Maintenance Routines Automatic Tank Gauge 7 1 Operation Check Check the operation of the gauge by rotating the gauge check knob on the front of the gauge The dial should show the movement of the float when the check knob is rotated Caution Do not release the gauge check knob and allow the springs to return the mechanism Over time t
63. er is removed 2 Remove the sixteen back cover bolts back cover and back cover gasket 1 3 If accessory equipment is attached to the gaugehead disconnect and remove 4 Attach the installation crank 5 Openan inspection hatch or manhole for access to the float Warning The rapid unwinding of the motor spring could result in the crank spinning and striking the operator Use a firm grasp on the crank Tighten thumbscrew to lock tape storage sheave before releasing grip Caution Allowing the float to fall back to the tank floor will likely damage the float Do not allow the float to fall back to the tank floor 6 Pull the float to the top of the tank while maintaining tape tension so that the tape feeds slowly back into the gaugehead 7 Secure the thumbscrew For Standard Model tighten thumbscrew to lock the tape storage sheave see Figure 3 1 item 3 For the Cassette Model align the locking pin with the keyhole 8 Secure float to top of tank with secondary wire Caution Allowing the float to fall back to the tank floor will likely damage the float Do not allow the float to fall back to the tank floor 9 Disconnect the perforated tape from the float connector 10 Attach a pull string to the tape to facilitate installing a new tape 11 Loosen the thumbscrew and slowly retract the tape into the gaugehead 12 Unwind the motor spring onto the motor storage sheave Figure 6 2 Caution When unsecured the perfo
64. fittings furnished by customer 1 1 2 Inch NPT coupling recommended 4 50 r7 114 4 50 B 24 00 610 Suggested L114 li Maximu m 36 00 i 914 8 00 n 16 00 T 203 406 Layout for pipe supports Minimum spaced approximately at 10 foot 3 meter intervals 6 00 152 Convenient eye level 14 50 368 an e Note Instalation hatch not shown Varec recommends installing a installation hatch 1 1 2 Inch NPT coupling furnished by customer V 25 Typical E Typical e 25 E 6 roof View C C Pipe Support Bracket Detail j ire eie 12 24 305 610 bv custo With float at bottom y LX of well m 1 Gaugehead 2 Float e 12 305 3 Tape Minimum with 4 Tape Cable fastner D float at product 5 Pipe Support Bracket level 8 Sheave elbow s 0 0 Unless otherwise noted i I 18 25 464 Over guide eyes Remove float guide eyes if necessary dimensions in inches millimters All welding by customer Figure 3 9 Cone Roof Tank with Internal Pan Floating Roof 20 Installation and Operations Manual 2500 ATG Installation 1 Gaugehead Note Instalation hatch not shown 1 1 2 Inch NPT coupling 2 Float Varec recommends installing recommended fu
65. fore it starts 9 1 Dials Do Not Respond When Gauge Check Knob is Rotated Caution Broken negator spring may cause injury Stand clear of gaugehead when removing back cover Possible Cause Action Tape broken Yes Replace tape Check attachment of negator motor to storage sheave Check for damaged gauge parts dial rotates No Go to 2 2 Negator motor broken Yes Replace negator Do not redrill or repair Wear gloves Check tape condition Check for damaged gauge parts No Go to 3 3 Tape rewound Yes Tape detached from float Replace tape and re attach Check for damaged gauge parts No Go to 4 4 Dials stopped Yes Check for frozen tape sprocket sheave shaft Repair replace Check for frozen accessory shaft Repair replace Check dial gear engagement with pinion gear Adjust replace Check gauge checker for broken spring and damaged ratchet pawl Replace No Go to 5 5 Counter dial wheels stopped Yes Check for worn broken counter pinion gear and counter wheels Replace as necessary Varec Inc 89 Troubleshooting Automatic Tank Gauge 9 2 Calibration Repeatability Unstable Caution Broken negator spring may cause injury Stand clear of gaugehead when removing back cover Possible Cause Action Dirty gauge housing Yes Clean with automotive type spray degreaser bearings No Go to 2
66. from the pinion gear Note To ensure the correct horizontal clearance keep the dial gear tooth away from the pinion gear until step 9 Ensure the correct vertical alignment between the dial gear and the pinion gear Varec Inc 67 Gaugehead Disassembly and Re assembly Automatic Tank Gauge 10 11 13 14 15 e If the dial gear is below the top of the pinion gear add shim washers 45 under the counter shaft assembly 11 as required If the dial gear is higher than the pinion gear remove shim washers from under the counter shaft assembly If no shim washers are present lightly tap the counter shaft assembly with a rubber mallet so that the dial gear and the pinion gear are level within 0 010 Slip the dial under the red pointer and onto the hub Turn the dial until the tab from the dial gear slips into the slot in the plate Install the dial retainer 9 and secure it with the three screws 40 Rotate the dial assembly to ensure that it does not bind on the pointer or pinion gear and that it advances the counter drum one digit as it crosses the zero position If the dial assembly is too loose or too tight adjust the positioning of the counter assembly 21 e The target clearance between pinion gear and dial gear is 0 010 Tighten the counter assembly screws 43 Rotate the counter drums to set the level to the correct value To complete the assembly refer to section 3 20 Initial Lubrication on page
67. g it into the hole in the roof Note Failure to place the coupling and pipe in a true vertical position may affect the accuracy of the gauge 6 After the coupling and pipe are checked to make certain that they are plumb unscrew the pipe from the coupling Note Make sure that the interior of all pipes are clean and corrosion free 7 Sealthethreads with pipe thread compound and reconnect the pipe to the coupling 22 Installation and Operations Manual 2500 ATG Installation 3 3 Tank Roof Entry Internal Pan Floating Roof 1 To facilitate inspection and service of the gauge system locate the well where gauge piping will pass over the top of the tank shell close to a stairway platform Note Due to the resulting gross measurement inaccuracies Varec does not recommend that the perforated tape tape cable be attached directly to a floating pan Use a covered floatwell for the best measurement accuracy 2 Determine the center point of the float well Varec recommends this position is located a minimum of 16 00 inches 406 mm and a maximum of 36 00 inches 916 mm from the wall of the tank 3 Provide the roof hole for the conduit pipework centered on this position For installations without guidewires only the center hole is required 4 Drill a small hole in the roof Check that a line dropped through this hole is plumb to the center point of the well If it lines up with the center point of the well enlarge the hole
68. ge 3 2 Tank Roof Entry Cone Roof Tank Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Note Varec recommends the installation of a manhole cover as shown in Figure 4 26 on page 48 1 Determine the position on the tank roof beneath which the center of the float will rise and fall Measuring Point Notice that this position is located a minimum of 16 inches 406 mm and a maximum of 36 00 inches 914 mm from the wall of the tank 2 Provide the roof holes centered on this position For installations without guidewires only the center hole for the tape pipe is required 3 X 2 00 Thru 51 4x 56 Thru 2 47 62 7 Typical Hi c MO On 3 50BC D Q O 89 Eoo j 8 50 8 50 3 Places 216 216 Figure 3 12 Hole Layout in Tank Roof for Top Anchors The float diameter is 14 50 inches 368 mm The guide cable holes are centered 8 50 inches 216 mm each side of the center of the float The tape pipe is centered on a 17 00 inch 432 mm diameter 3 If performing a Bolted Cone Roof type installation check the angle of the roof The supplied mounting bracket for the gaugehead is designed for a 1 12 roof pitch 1 inch 25 mm rise over 12 in 300 mm run 4 Screw the drop pipe coupling into the vertical pipe nipple This will aid in positioning the coupling while welding 5 Check the pitch of the roof Hold the coupling plumb while weldin
69. gehead English Configuration Negator Motor 10 Tank Type TOI Standard service cone roof tank TO2 Standard service cone roof tank with pan amp floatwell T03 Standard service floating roof tank amp floatwell T04 Standard service tank top mounting T05 Standard service bolted tank TO6 Standard service floating roof tank no floatwell TO7 Standard service cone roof tank amp pan no floatwell T41 Moderate service cone roof tank T51 Interface service cone roof tank 15 min s g differential T52 Interface service cone roof tank 25 min s g differential T55 Stilling well service cone roof tank 6 dia float N250001 Complete product designation 11 2 Aluminum Gaugehead Metric Configuration Negator Motor 10 Tank Type T11 Standard service cone roof tank T12 Standard service cone roof tank with pan amp floatwell T13 Standard service floating roof tank amp floatwell T14 Standard service tank top mounting T15 Standard service bolted tank T16 Standard service floating roof tank no floatwell T17 Standard service cone roof tank amp pan no floatwell T42 Moderate service cone roof tank T53 Interface service cone roof tank 15 min s g differential T54 Interface service cone roof tank 25 min s g differential T56 Stilling well service cone roof tank 6 dia float N250003 Complete product designation 11 3 Aluminum Gaugehead Englis
70. h Configuration Float Crank 10 Tank Type TOI Standard service cone roof tank TO5 Standard service bolted tank N250002 Complete product designation 11 4 Aluminum Gaugehead Metric Configuration Float Crank 10 Tank Type T11 Standard service cone roof tank N250004 Complete product designation Varec Inc 95 Order Codes Automatic Tank Gauge 11 5 Iron Gaugehead English Configuration 10 Tank Type T21 T22 T23 T24 Severe service cone roof tank SS316 Extreme service cone roof tank monel Extreme service cone roof tank carp 20 Severe service tank top mounting N250005 Complete product designation 11 6 Iron Gaugehead Metric Configuration 10 Tank Type T31 T32 T33 T34 Severe service cone roof tank Severe service tank top mounting Extreme service cone roof tank monel Extreme service cone roof tank carp 20 N250006 Complete product designation 11 7 Aluminum Gaugehead English Configuration Negator Cassette 10 Tank Type TOI T02 T03 T04 T05 T06 T07 T41 T55 Standard service cone roof tank Standard service cone roof tank with pan amp floatwell Standard service floating roof tank amp floatwell Standard service tank top mounting Standard service bolted tank Standard service floating roof tank no floatwell Standard service cone roof tank amp pan no floatwell Moder
71. h a pipe thread compound and reconnect the pipe to the flange 24 Installation and Operations Manual 2500 ATG Installation 3 5 Correct Float Positioning for an External Floating Pan Installation Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Note To facilitate inspection and service of the gauge system locate the well where gauge piping will pass over the top of the tank shell close to a stairway platform Note The total float travel distance must be less than the height of the outboard vertical pipe This allows the tape and tape cable splice to reside in the vertical pipe throughout the total travel of the roof 1 Determine the position of the center point at which the float will rise and fall center point of the floatwell or point on the pan where the cable will attach Varec recom mends this position is located a minimum of 16 inches 406 mm and a maximum of 36 inches 916 mm from the wall of the tank 2 Extend a vertical line from this point up to the tank roof position of the support brackets that will hold the conduit Varec Inc 25 Installation Automatic Tank Gauge 3 6 Installing Anchors and Guidewires Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding 1 Center the base of a top cable anchor in its hole Hold it plumb while welding or bolting it to the roof
72. h the level reading recorded before disassembly 19 If necessary adjust the gauge level reading to match the pre disassembly reading 20 To complete the assembly refer to section 3 20 Initial Lubrication on page 43 That section gives instructions to reset and calibrate the counter install transmitters and other auxiliary equipment and replace the back cover Note Torque back cover bolts to 6 ft lb Do not over torque 21 Refill gaugehead with oil if required 22 Close the tank inspection hatches and manholes Varec nc 51 In Service Installation Procedures Automatic Tank Gauge 4 2 Oil Seal Installation For tank configurations that include oil seal accessories refer to these illustrations and perform the installation procedures included in this section For most installation use a low pour point food grade water white mineral oil Examples are provided in section 7 7 Lubrication on page 71 4 2 1 27 inch Water Column Operating Pressure Oil Seal ITEM DESCRIPTION 1 180 Elbow 2 Pipe 1 1 2 inch NPT X 38 965 long 3 Pipe 1 1 2 inch NPT X 32 813 long 4 180 Elbow with drain 10 50 267 6 00 152 7 Lh 1 1 2 Inch NPT T q eT 90 elbow furnished with Model 2500 mounting kit 1 1 2 Inch NPT pipe both ends X 43 1092 long furnished by customer 53 00 1346 P5 9 qe 1 2 Inch NPT d
73. h the top anchor assembly Hand tighten 9 Usethe lock nut to lock the cable in place and then tighten the adjustment nut until the guide cable is tensioned by the spring 10 Trim off excess cable and replace the housing nipple and cap 26 Installation and Operations Manual 2500 ATG Installation 3 7 Installing Support Brackets amp Pipework Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Note The pipe carrying the perforated tape must be attached to the tank by welding the supplied brackets If the environment is such that welding cannot be performed the user can construct a support structure with 3 inch 76 mm pipe or conduit close to the outside of the tank The brackets can be welded to the support structure at another location if necessary and the pipe structure assembled at the tank site 1 Weld or bolt the pipe support brackets into place When installing the conduit pipe work start installing conduit and sheave elbows from the tank entry point to the gaugehead at grade level 2 Apply pipe thread compound and install the sheave elbow on the vertical pipe to the tank interior then install the horizontal pipe into that elbow
74. hand crank for any installation that directly attaches the tape tape cable to a floating roof Damage to the gauge may result The hand crank gaugehead should not be used in this type of installation 38 Installation and Operations Manual 2500 ATG Installation Ensure that the hand crank is in the engaged position To engage push the ratchet pawl lever up and push the crank handle hub inward until the ratchet pawl engages the ratchet gear To wind the motor turn the crank the number of times indicated in Table 3 3 Turns to Wind Negator Motor Turn until the motor is wound and the ratchet pawl is at mid position engaged Table 3 3 Turns to Wind Negator Motor Motor Sheave Part Gaugehead Motor Normal Application Turns with Float Crank No hand crank turns BA7762 Standard 0 60 0 18m tank range 120 BA17725 Extra Strong 0 60 0 18m tank range 125 BA17087 Extra Long 0 96 0 29m tank range 168 Perform the procedure in section 3 16 to install the tape in the gaugehead Hold the crank handle firmly and hold the ratchet pawl up Crank clockwise to lower the float to the bottom of the tank while observing the tape travel through the elbows and gaugehead There should be no binding Disengage the hand crank To disengage hold the ratchet pawl lever up pull outward on the crank handle hub until the gear is disengaged Then push the ratchet pawl lever down Varec nc
75. hecklist from section 2 4 before proceeding Note At this point the tape cable should be connected to the float Note The following steps explain how to feed the tape through the conduit from the tank entry point or roof position to the gaugehead at grade level 1 Spread a clean ground cloth below the gaugehead and remove the lower tape hole pipe plug 2 Feed the other end of the tape over the tank entry elbow sheave through the horizontal pipe 3 and over the sheave in the outboard elbow Figure 3 21 Feed the tape through the conduit to the gaugehead 3 Lower the tape through the exterior pipe 4 and down through the gaugehead and lower tape hole then onto the ground cloth s until the tape is unrolled Make sure that the tape does not become 5 kinked or dirty 4 Check the perforated tape length and trim if necessary Note Trimming the tape shorter than 6 feet could result in the tape end retracting up into the conduit 5 Ifthe tape extends more than 6 feet 1 8 M below the gaugehead when it is at zero level trim the excess Trim the tape about 6 feet 1 8 M from the bottom of the gaugehead 6 To install the perforated tape in the gaugehead proceed to the section for your type of gaugehead e Fora Standard 2500 ATG with a Negator Spring Motor go to section 3 16 e Fora 2500 ATG with Negator Cassette go to section 3 16 2 e For a Hand Crank Type Gaugehead Install
76. her 4 on the counter shaft assembly 11 Place the sprocket sheave assembly on the counter shaft assembly 11 Place the tape storage sheave assembly on the lower shaft Place the motor storage sheave assembly 48 on the upper right shaft Align the motor storage 48 and the tape storage sheave assemblies Ensure that the bottom of the motor storage sheave flange is 0 040 to 0 060 clear of the top surface of the tape storage sheave Adjust height by using shim washers 45 as required Align the groove center line of the sprocket and the tape storage sheave assem blies Ensure that the top surface of the sprocket sheave flange is 0 030 to 0 040 below the top surface of the tape storage sheave flange Adjust height by using shim washers 45 as required When properly aligned tighten the set screw 28 in the sprocket sheave assembly 18 Test that the counter assembly 21 functions properly with no axial play in the counter shaft and sheave assemblies Remove the motor storage sheave assembly 48 from the gaugehead Assemble tape keeper assembly 16 containing items 27 16 28 Apply Loctite 262 or equal to screw threads and thread assembly into the gaugehead body Adjust the tape keeper spring for a clearance of 0 020 to 0 030 against the sprocket sheave assembly Place the motor storage sheave assembly 48 back into the gaugehead Secure the tape storage sheave assembly with retaining ring 23 Use washer
77. his will cause the springs to break and will jam the gauge Caution Do not turn the gauge check knob on systems that have no float and that are directly connected to a floating roof 7 2 Leak Check Check the gaugehead and conduit for signs of leaking for example look for cracks or corrosion that may cause the product to leak If the gaugehead is oil filled check for signs to assure that the gaugehead is not leaking oil 7 3 Sediment Check Remove the NPT fitting on the bottom of the gaugehead and check for sediment 7 4 Deformation Check Check the conduit for deformations that might inhibit the movement of the tape 7 5 Calibration Check Check the accuracy of the gauge against a hand dip measurement in the tank and calibrate the gauge if necessary Refer to section 3 18 on page 41 for calibration instructions 7 6 Float and Guidewires Check Using a manway or inspection cover for access check the guidewires and float The guidewires should be tight and free of kinks to allow the float to run freely Check the guidewires and float for sediment that might inhibit movement 70 Installation and Operations Manual 2500 ATG Maintenance Routines 7 7 Lubrication Caution Do Not use any type of grease WD 40 or lithium based lubricant Warning Before lubrication ensure the chemical compatibility of the lubricant with the product in the tank Lubricate the moving parts of the gaugehead at regular inte
78. how decimal units All dial counters reflect product innage For outage reading requirements Varec offers a conversion kit Part 13 08774 for English units of measure only 1 3 2 Check Knob An operation checker provided as a standard feature on both the 2500 and 2520 ATG permits your technician to check the instrument for correct operation 1 3 3 Negator Cassette The negator cassette improves the performance of your mechanical tank gauge by self aligning the tape and motor as it provides the constant pullback tension required for the float to follow the liquid level The cassette increases reliability and reduces maintenance by protecting internal moving parts from pipe debris that could cause stretching or corrosion It also allows for safer easier and quicker service because there is no tape to pull out or negator hubs to unwind in your hands 1 3 4 Float Crank The float crank allows your operators to manually raise and lower the float This can be useful during turbulent mixing conditions so that the float or tape is not damaged Varec Inc 3 Introduction Automatic Tank Gauge 4 Installation and Operations Manual 2500 ATG General Preparation 2 General Preparation 2 1 2 2 Safety Precautions Before installing your 2500 ATG read and review the Safety Precautions on page ii of the preface to this document Continuing with installation according to the instructions in this manual presumes you have reviewed thes
79. ht can be used as an alternative when the installation is performed while the tank is in service Part BA4481 Installation and Operations Manual 2500 ATG General Preparation 2 3 3 2 3 4 Varec top guidewire anchors can be screwed or welded into the tank roof maintenance hatch or manhole cover Support Brackets A frame brackets support the conduit pipework that carries the tape These brackets can be welded or bolted to the tank and should be placed at regular intervals approx 10ft or 3 meters to provide uniform support The pipework should be held rigidly in place and correctly aligned so that the tape does not touch or rub the internal pipework Side H bracket Ve The steel pipe support bracket is used on the side of the tank Part B5643 003 The upper support bracket assembly is used at the tank top Part 4BM71 7 Figure 2 4 Support brackets and conduit shown on an external floating roof tank Conduit Pipework and Couplings Plan the pipe routing and make sure you have the required conduit elbows and other materials needed Couplings can be used to easily connect sections of pipework together without welding They also provide a means to maintain the pipework tape and gaugehead Vertical runs must be plumbed to be perpendicular to prevent the tape from binding inside the pipe The pipe carrying the perforated tape must be attached to the tank b
80. ic gravity of water 1 0 The value set on the dial plate 7 is the waterline level on the float as it contacts the bottom of the tank Refer to the table below to determine the setting for the dial plate Be careful not to pull up and disengage or drop the pinion gear 24 If the pinion gear is disengaged it may be necessary to disassemble and reassemble the counter mechanism to properly calibrate the gauge Refer to Chapter 6 3 if this becomes necessary If the dial and counter drums have not been reset to zero as described in the preceding section perform those steps first The counter must be re calibrated after product is placed in the tank 1 Determine the value at which to set the dial You can determine the value from the table b elow or from specific gravity tables for the product that will be or is in the tank Alternatively use a hand gauge to determine product level 2 Rotate Note the dial to the determined value If it is necessary to disassemble the counter mechanism refer to figure 1 6 or for more instruction detail refer to the Service Manual SRM001GVAE0408 3 Tighten the dial plate screws 40 being careful not to overtighten them Table 3 4 Initial Calibration Table Gaugehead Units x Minimum Counter Drum Dial Setting Corresponding Increment Settings s g 1 0 Measure ft amp in x 1 16 in 0 0 2 2 inches ft amp 1 10 ft x 1 100 ft 0 0 16 5
81. ing manway Each or the three port entries is threaded for simple installation of pipework or guidewire anchors Part BM3443 for 20 Part BM3607 for 24 An inspection cover Model 228 can be installed onto an existing manhole cover to provide an easily removable inspection plate Part BM6746 Figure 2 6 Inspection and manhole covers Floats For new installations locate the float in the tank where it will be exposed to a minimum of agitation If the product stream is close to the float install a deflector If agitators will cause excess float disturbances contact Varec before proceeding with installation The 2500 ATG is provided with a standard 17 432 mm diameter Type 316 stainless steel hollow shell float Depending on the type of service kit selected moderate severe or extreme an alternative float may be supplied Figure 2 7 Standard 2500 ATG flat hollow shell float and 6 interface float e Installation and Operations Manual 2500 ATG General Preparation 2 4 Identifying Your Installation Type Various accessories are provided depending on the installation type selected in the product order codes 2 4 1 Cone Roof Tank Order Code T01 T11 T21 T22 T23 T24 T31 T33 T34 T41 T42 Installation parts supplied include 90 Elbow assembly x2 Gauge U bolt kit Guidewire bottom anchor Guidewires Support bracket x6 Gaugehead and tape
82. k Gauge 2 3 Guidelines Recommendation and Options When Preparing for Installation 2 3 1 2 3 2 Various installation options and accessories are available to suit user installation requirements This section provides an overview and basic recommendations for elements of a 2500 ATG installation It is paramount that the user monitor the quality of the installation to assure long term accurate performance All parts of the gaugehead tape and float should move freely to reduce wear and maintenance If the quality is compromised inferior operation may result How a guidewire is anchored at the tank bottom and welding parts to or in the tank are major considerations These additional items are also critical to successful installation and operation of the 2500 ATG Accurate hand gauging referenced to the tank bench mark Clean interior of the gauge piping No kinks in the tape or tape cable No noticeable binding friction in the mechanism Installation cleanliness True vertical gauge piping Location of float away from inlet pipes of mixers Note Varec service contracts provide the user substantial savings for maintaining and refurbishing the systems already in service Floating Roof Tank Installations Warning In floating roof tank installations do not connect the tape cable directly to the tank roof Varec recommends that gauges be installed in a floatwell rather than attaching the tape directly to the tank roof
83. ket sheave Elbow 2 na SRMOO1 Service Manual 78 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits When performing extended maintenance Varec also recommends replacing the tape or the tape and cable combination as shown in the following table Table 8 6 Additional Items Recommended for Extended Maintenance Item Part No Description EE B7650 606 Tape Imperial Length 136 316 SS for a tank 60 ft high B7650 306 Tape Imperial Length 80 316 SS for a tank 32 ft high B9736 606 Tape Metric Length 41 25 m 316 SS for a tank 18 29 m high B9736 306 Tape Metric Length 24 38 m 316 SS for a tank 9 75 m high FF B7678 606 Tape and Cable 3 32 Combination Imperial Length 133 for a tank 60 ft high B7678 306 Tape and Cable 3 32 Combination Imperial Length 73 for a tank 30 ft high B13982 606 Tape and Cable 3 32 Combination Metric length 44 5 m for a tank 18 m high B7678 106 Tape and Cable 3 32 Combination Imperial Length 73 for a tank 30 ft high B13982 306 Tape and Cable 3 32 Combination Metric Length 22 2 m for a tank 9 m high Varec Inc 79 Automatic Tank Gauge Spare Parts and Maintenance Kits peuinbaJ se gp pue pp sway asf jeJoN SI sued ees SWd Jeuyo sepnjour Ajqwassy A quiessy duie 2 edej Jexses Je
84. l Carp 20 Standard float 316 S S 316 S S 316 S S Monel Carp 20 10 8 Oil Seals Part Material Oil seal 10 01994 AAA Aluminum 8 5 216mm Water column operating pressure 10 01994 BAA Cast iron 8 5 216mm Water column operating pressure 10 02861 AAA Aluminum 27 686mm Water column operating pressure Varec Inc 93 Specifications and Reference Data Automatic Tank Gauge 10 9 Approvals Item Description Approval Type FM 06 ATEX 0009 Approval Certificate Number FMO6ATEX0009 Product Option Codes N250001 2500 Automatic Tank Gauge English Negator Motor N250002 2500 Automatic Tank Gauge English Float Crank N250003 2500 Automatic Tank Gauge Metric Negator Motor N250004 2500 Automatic Tank Gauge Metric Float Crank N250005 2500 Automatic Tank Gauge English Iron Gaugehead N250006 2500 Automatic Tank Gauge Metric Iron Gaugehead N250011 2500 Automatic Tank Gauge English Negator Cassette N250013 2500 Automatic Tank Gauge Metric Negator Cassette 10 100ther Specifications Item Material Service Rating 2 1 2 PSIG Pipe Connections 1 1 2 inch NPT Maximum Tank Height 60 feet 18 2 m Shipping Weight 70 Ibs 33 kg nominal weight increases with various kits 94 Installation and Operations Manual 2500 ATG Order Codes 11 Order Codes 11 1 Aluminum Gau
85. llation and Operations Manual 2500 ATG In Service Installation Procedures 4 In Service Installation Procedures Note Before installing your 2500 ATG read and review all safety precautions on page ii of the preface to this document Continuing with installation according to the instructions in this manual presumes you have reviewed these safety precautions Note Refer to section 2 4 Identifying Your Installation Type on page 9 before proceeding Warning Make certain that the tank has been leak and pressure tested as appropriate for the liquid stored Observe appropriate safety precautions in flammable or hazardous liquid storage areas Warning Do not enter a tank that contains hydrocarbons vapors or toxic materials until a gas free environment is certified Carry breathing equipment when entering a tank where oxygen may be displaced with carbon dioxide nitrogen or other gases or toxic fumes may be present Warning The mechanical connections between the guide cables the float the tape and the gaugehead provide a resistance to ground that is adequate for the safe electrical drain of electrostatic charges that may accumulate in the tank and the product Worker activity and worker clothing may accumulate electrostatic charges on the body of a worker Care should be used in flammable environments to avoid the hazard Observe American Petroleum Institute API Recommended Practice 2003 or other appropriate industry or Military Stand
86. motor The precisely perforated tape engages pins on a sprocket wheel that in turn drive the counter assembly This simple design and operation allows the gauge to perform with negligible maintenance throughout its working life Sprocket Wheel Perforated Tape Mechanical Counter Figure 1 2 2500 ATG Powered by Negator Motor Calibration and Volume Measurement Tank gauging measurements provide appropriate inventory checks and a valuable method of checking marine receipts and metered custody transfers Accuracy of measurements requires that a number of factors be considered No Electricity Required Density and specific gravity of product as determined from representative samples Sediment in the tank Water content in the product Gross volume Temperature of the product Tank bottom deformation It is the user s responsibility to appropriately consider these and other factors in this application For example oil tank capacity tables are calculated for product at 60 F A higher temperature will cause the tank to expand and the actual volume will be greater than the volume at the standard temperature API Standard Description 2550 Method For Measurement And Calibration Of Upright Cylindrical Tanks ANSI ASTM D1220 2545 Method of Gauging Petroleum and Petroleum Products ANSI ASTM D1085 2540 Chapter 11 1 ANSI ASTM D1250 for Volume Correction Factors Refer also to API 2545
87. ms and dial 7 to zero or to the calibrated liquid level m 2 Hub Assembly L i Y bl bib i bl bib Figure 6 3 Counter Wheel Assembly 1 Place counter assembly 21 on supports and loosely install three mounting screws 43 Do not tighten the screws With the pinion gear removed rotate the counter assembly drums to display a whole number The red tipped pointer will be aligned with the center point between two teeth on the counter drum gear Examine the pinion gear Note that from the top side alternate teeth are high or low From the bottom side the 8 teeth are evenly aligned With right thumb and finger pick up the pinion gear by two of the high teeth and with the top side facing up Install the pinion gear on the counter base shaft Set the gear with the 8 tooth side down against the counter base and so that the left facing low tooth fits between two teeth of the counter drum gear Note The tops of the three teeth 1 pinion gear tooth and 2 counter drum gear teeth should be aligned If they are not you may have set the pinion gear 1 2 notch out of position and the counter display will also be off by that much Set the dial gear on the dial assembly hub without meshing the pinion gear teeth Setthe dial gear with its tooth up and turned away
88. n un Guide cable 14 Places i anchor nipple 15 75 1400 6 00 152 2 50 Thru D Cover rd S gt Cover cutout 63 5 7 1 1 2 Inch coupling gt i i by customer 8 5 8 5 1 Frame Assembly 4 Hex head cap screw 1216 216 2 Cover 5 Hex nut 3 Gasket Figure 4 30 Manhole Cover and Inspection Hatch 54 Installation and Operations Manual 2500 ATG In Service Installation Procedures 4 4 Guidewire Bottom Anchors Varec supplies an anchor bar for in service installations Part Number BA4481 that must be ordered separately It is for normal service only The guide cables fasten to the anchor bar with cable clamps see Figure 3 14 For severe or extreme service installations contact Varec The Bottom Anchor Bar is made of cast iron and weighs 52 Ibs 22 2 kg Figure 4 31 Typical Anchor Installment with Cable Clamps on left view Varec Inc 55 In Service Installation Procedures Automatic Tank Gauge 4 5 In service Float amp Guidewire Installation 6 Refer to appropriate tank configuration and if required install top anchors less long nipple and cap Thread the float guide cables into the tank through the top anchor fittings and pull the ends back through the inspection hatch Fasten the bottom anchor to the guide cables see Figure 4 31 and lower the anchor slowly through the inspection hatch into the tank When anchor bar is resting on tank bottom remove cable slack by han
89. nearest the counter base Mesh the short tooth of the pinion gear into the counter wheel gear 16 Place dial gear 5 with registering tab downward on the counter shaft assembly 11 e If the dial gear is below the top of the pinion gear add shim washers 45 under the counter shaft assembly 11 as required If the dial gear is higher than the pinion gear remove shim washers from under the counter shaft assembly If no shim washers are present lightly tap the counter shaft assembly with a rubber mallet so that the dial gear and the pinion gear are level within 0 010 17 Adjust the dial gear 5 and the counter assembly 21 for a clearance of approxi mately 0 010 between the pinion gear 24 and the dial gear 5 These two gears should engage securely but without any binding Rotate the dial gear to check that all gears mesh smoothly and that the counter wheels operate correctly 18 Tighten the three screws 43 mounting the counter assembly Varec Inc 65 Gaugehead Disassembly and Re assembly Automatic Tank Gauge 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Slip the dial 7 under the red pointer of the counter assembly and onto the hub Rotate the dial until the tab from the dial gear 5 registers with the slot in the dial Install dial retainer 9 on dial 7 and secure it with three screws 40 Place washer 37 and Teflon was
90. nment is certified Carry breathing equipment when entering a tank where oxygen may be displaced by carbon dioxide nitrogen or other gases Wear safety glasses as appropriate Use a hard hat Installation and Operations Manual 2500 ATG Warning Warning Sparks or static charge could cause fire or explosion The mechanical connections between the guide cables the float the tape and the gaugehead provide a resistance to ground that is adequate for the safe electrical drain of electrostatic charges that may accumulate in the tank and the product Worker activity and worker clothing may accumulate electrostatic charges on the body of a worker Care should be used in flammable environments to avoid the hazard Broken negator motor spring pieces can cause injury when the back cover of the gaugehead is removed Whenever the back cover is removed stand to one side as the last bolt is removed Varec nc Automatic Tank Gauge Installation and Operations Manual 2500 ATG 1 CIDnIrOdU CUOI Mitte cotes Bota Cet a ate CLEA its ds 1 1 4 Using this Manual lle 1 1 2 Getting Acquainted with the 2500 Automatic Tank Gauge Systems 1 1 2 1 Tank Gauge Operation llle 2 1 2 2 Calibration and Volume Measurement 000 ee eee eens 2 1 2 8 System Integration 2 lille 3 4 97 Product Options s 3 259 n ubpd ae bee ah Pe ee a ae he 3 1 3 1 English and Metric Configurations
91. nt brush and apply white silicone grease to the gaugehead body seal recess 2 Carefully press the counter shaft seal into place with cavity facing outwards 3 If gauge check knob Teflon o ring 26 is being replaced lubricate o ring with white silicone grease 4 Carefully install the gauge check knob o ring into the inside gaugehead body recess 5 Lubricate Viton o ring 22 with white silicone grease and carefully insert it into the outside gaugehead body groove 6 Assemble gauge check hair spring 62 and shim washer 33 on the gauge check assembly 14 7 Lubricate the shaft 60 with white silicone grease and insert it into the body 8 Install shim washer 33 and grip ring 29 to the external shaft projection of the gauge check assembly 14 9 Place gauge check knob 13 with set screw 42 on the external shaft projection of the gauge check assembly 14 10 Tighten set screw making sure it contacts the flat edge on the shaft 11 Turn the knob in turn intervals to ensure smooth operation 12 Replace any previous shim washers 45 on counter shaft assembly 11 and brush the shaft with white silicone grease Install counter shaft assembly into the body 13 Place counter assembly 21 on supports and loosely install three mounting screws 43 Do not tighten the screws 14 Align counter assembly wheels to zero 15 Install pinion gear 24 on counter base shaft locating the 8 tooth side of the gear
92. on Negator Motor 95 11 3 Aluminum Gaugehead English Configuration Float Crank 95 11 4 Aluminum Gaugehead Metric Configuration Float Crank 95 11 5 Iron Gaugehead English Configuration 20 000 ee eee 96 11 6 Iron Gaugehead Metric Configuration 0000 0 eee ee 96 11 7 Aluminum Gaugehead English Configuration Negator Cassette 96 11 8 Aluminum Gaugehead Metric Configuration Negator Cassette 96 viii Installation and Operations Manual 2500 ATG Introduction 1 Introduction 1 1 Using this Manual This manual is designed to assist the user in the installation operation maintenance and troubleshooting of low pressure 2500 Automatic Tank Gauges Former 2600 Series gauges with a hand crank are included These gauges are for use at atmospheric pressure or at low pressure 2 5 psig Medium and high pressure tanks are served by the 2520 ATG gauges for pressure vessels to 300 psig and are covered in their respective product manuals Proper operation of the gauge requires the user to pay serious attention to assuring high quality control during the installation Long term satisfactory performance of the gauge can thus be obtained If the installation quality is compromised gauge accuracy and life may be degraded Varec service contracts provide the user substantial savings for maintaining and refurbishing
93. page 34 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 Section 3 16 Install Tape in the Gaugehead on page 36 Section 3 18 Reset the Counter on page 41 Section 3 19 Calibrate the Counter on page 42 Section 3 20 Initial Lubrication on page 43 Section 3 21 Install a Transmitter and Replace all Covers on page 44 Section 3 22 Initial Operation on page 45 14 Installation and Operations Manual 2500 ATG General Preparation 2 4 7 External Floating Roof Tank and Floatwell Order Code T03 T13 Installation parts supplied include 90 Elbow assembly x2 amp conduit connector kit Gauge U bolt kit Support bracket assembly Support bracket x6 Gaugehead and tape cable Float Tape cable connectors Conduit connector kit 2 4 7 1 Installation Checklist When installing a 2500 ATG system on a External Floating Roof Tank and Floatwell complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Description Complete 1 Section 3 5 Correct Float Positioning for an External Floating Pan Installation on page 25 2 Section 3 7 Installing Support Brackets amp Pipework on page 27 3 Section 3 8 Installing a Gaugehead at G
94. page 45 10 Installation and Operations Manual 2500 ATG General Preparation 2 4 8 Cone Roof Tank with Internal Floating Roof Pan and Floatwell Order Code T02 T12 Installation parts supplied include 90 Elbow assembly x2 Gauge U bolt kit Support bracket x6 Gaugehead and tape cable Float Tape cable connectors Conduit connector kit 2 4 3 1 Installation Checklist When installing a 2500 ATG system on a Cone Roof Tank with Internal Floating Roof Pan and Floatwell complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Step Description Complete 1 Section 3 3 Tank Roof Entry Internal Pan Floating Roof on page 23 2 Section 3 7 Installing Support Brackets amp Pipework on page 27 3 Section 3 8 Installing a Gaugehead at Grade Level on page 28 4 Section 3 10 Float installation on an Out of Service Tank on page 30 5 Section 3 12 Connecting the Cable to a Float in a Floatwell on page 32 6 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 7 Section 3 16 Install Tape in the Gaugehead on page 36 8 Section 3 17 Trimming the Cable at the Float in a Floatwell on page 40 9 Section 3 18 Reset the Counter on page 41 10 Section 3 19 Calibrate the Counter on page 42 11 Section
95. phere interface f duct tact fact BM17782 006 316 SS a ce C Ed 6 152 mm Sphere interface BM17783 006 316 SS 10 254 mm Sphere interface P29 43 Fibre glass 9 Ib 17 432 mm Flat 92 Installation and Operations Manual 2500 ATG Specifications and Reference Data 10 6 Conduit Elbows Part Angle Description Pressure Rating Conduit Material Wheel Material BM3661 90 Elbow 150 PSIG 1 1 MPa Cast iron 316 SS BM3491 90 Elbow 300 PSIG 2 2 MPa Cast iron 316 SS BM3490 45 Elbow 300 PSIG 2 2 MPa Cast iron 316 SS BM3489 30 Elbow 300 PSIG 2 2 MPa Cast iron 316 SS 06 08564 90 Elbow Atmospheric Aluminum Delrin 06 07726 90 Elbow Atmospheric Aluminum 316 SS BM4675 90 Elbow Atmospheric Cast iron 316 SS BM5074 90 Elbow Atmospheric 316 Stainless steel 316 SS BM3480 135 Elbow Atmospheric Aluminum Delrin BM3481 180 Elbow Atmospheric Aluminum Delrin BM3621 NA Tape carrier Atmospheric Aluminum Delrin 10 7 Standard Installation Kits Description Standard Moderate Severe Extreme NaOH Extreme H2SO4 Gaugehead Aluminum Aluminum Cast iron Cast iron Cast iron Elbow assembly Aluminum 316 S S Cast iron Cast iron Cast iron Top anchors Steel 316 S S Steel Steel Stl Carp 20 Guidewire weight Steel 316 S S 316 S S Monel Carp 20 Guidewires 316 S S 316 S S 316 S S Monel Carp 20 Perforated tape 316 S S 316 S S 316 S S Mone
96. place it 30 Do not reuse the Teflon o ring if it is removed The gauge check knob shaft Teflon o ring 26 on the inside of the gaugehead is pressed into place with a special setting tool If replacement is required call Varec for maintenance Remove Teflon o ring 26 only if gaugehead showed signs of leakage Caution Do not remove the counter shaft seal before assessing the need to replace it Do not reuse the counter shaft seal if it is removed The counter shaft seal 12 is pressed into place If replacement is required call Varec for maintenance Note Do not remove the bushings from the counter shaft 31 The counter shaft brass bushings are pressed into the bore with special press fixtures Clean the disassembled gaugehead and any parts that will be reused with a com mon automotive type spray or dip degreaser Clean and wipe dry in accordance with the directions of the product used 64 Installation and Operations Manual 2500 ATG Gaugehead Disassembly and Re assembly 6 2 Gaugehead Assembly Unless otherwise labelled numbers in parentheses 12 for example refer to the item callout numbers on Figure 6 1 or Figure 6 2 Perform the following steps to reassemble the gaugehead When white silicon grease is called for use Dow Corning 4 or equivalent Note Generally assembly is performed in the reverse order of disassembly 1 If counter shaft seal 12 is being replaced use a clean small pai
97. r knob on systems that have no float and that are directly connected to a floating roof 3 Turn the operation checker knob on the front of the gaugehead of non crank types a quarter turn clockwise to lift the float slightly Check that the display registers the movement Caution For hand crank gaugeheads do not disengage the crank while the float is above the surface of the liquid Do not allow the float to free fall Damage to the system may result 4 For hand crank gaugeheads engage the crank to make the check then disengage the crank To engage the crank hold the ratchet pawl in the disengaged position upward and push in on the hub of the crank assembly To disengage the crank make certain the float is on the surface of the liquid by rotating it slowly until the counter stops Do not continue to crank 5 To disengage hold the ratchet pawl lever up pull outward on the crank handle hub until the gear is disengaged Then push the ratchet pawl lever down Note If the tape becomes slack with the float on the surface the tape may slip off the elbow pulley the tape storage sheave or the tape keeper If this occurs refer to Trouble shooting 6 Continue filling the tank to the desired level 7 Hand gauge the product and compare the measurement with the display If they do not coincide refer to Section 3 18 Reset the Counter on page 41 Varec nc 45 Installation Automatic Tank Gauge 46 Insta
98. ra is a registered trademark of Old World Industries Northbrook IL ARCO is a registered trademark of Atlantic Richfield Company Los Angeles CA PENSKE is a registered trademark of Penske Corporation Bloomfield Hills MI ZEP is a registered trademark of E I du Pont de Nemours Co Inc Wilmington DL Disclaimer of Warranties The contract between the Seller and the Buyer states the entire obligation of the Seller The contents of this instruction manual shall not become part of or modify any prior or existing agreement commitment or relationship between the Seller and Buyer There are no express or implied warranties set out in this instruction manual The only warranties that apply are those in the existing contract between the Seller and Buyer The 2500 Automatic Tank Gauge ATG has not been tested by Varec under all possible operational conditions and Varec may not have all the data relative to your application The information in this instruction manual is not all inclusive and does not and cannot take into account all unique situations Consequently the user should review this product literature in view of his her application If you have any further questions please contact Varec for assistance Limitations of Seller s Liability In the event that a court holds that this instruction manual created some new warranties Seller s liability shall be limited to repair or replacement under the standard warranty Varec nc
99. rade Level on page 28 4 Section 3 10 Float installation on an Out of Service Tank on page 30 5 Section 3 12 Connecting the Cable to a Float in a Floatwell on page 32 6 Section 3 15 Feeding the Tape to a Gaugehead Located at Grade Level on page 35 7 Section 3 16 Install Tape in the Gaugehead on page 36 8 Section 3 17 Trimming the Cable at the Float in a Floatwell on page 40 9 Section 3 18 Reset the Counter on page 41 10 Section 3 19 Calibrate the Counter on page 42 11 Section 3 20 Initial Lubrication on page 43 12 Section 3 21 Install a Transmitter and Replace all Covers on page 44 13 Section 3 22 Initial Operation on page 45 Varec Inc 15 General Preparation Automatic Tank Gauge 2 4 8 External Floating Roof Tank No Floatwell Order Code T06 T16 Installation parts supplied include 90 Elbow assembly x2 amp conduit connector kit Gauge U bolt kit Support bracket assembly Support bracket x6 Gaugehead and tape cable Tape cable connectors Conduit connector kit 2 4 8 1 Installation Checklist When installing a 2500 ATG system on a cone roof tank complete each installation step below Check off a step when it is complete Refer to Section 3 1 Installation Schematics on page 20 for overall dimensions Note Due to the resulting gross measurement inaccuracies Varec does not recommend that the perforated tape tape cable be attached directly
100. rain plug 4 00 i 102 Approximate L 1 1 2 inch NPT coupling furnished by customer Figure 4 28 Installation of Oil Seal 27 inch Water Column Operating Pressure Oil Seal 1 Apply appropriate pipe compound and install short pipe 3 into 180 degree elbow 1 2 Apply pipe thread compound and install 180 degree elbow 4 onto short pipe 3 3 Apply pipe thread compound and install long pipe 2 into elbow 4 4 Apply pipe thread compound and install 90 degree elbow supplied with gauge kit onto long pipe 2 5 Complete the assembly to the user furnished 1 5 inch pipe 52 Installation and Operations Manual 2500 ATG In Service Installation Procedures Adjust the assembly to provide the tape tape cable path illustrated Proceed with the remainder of the tank installation to the paragraph Initial Lubrica tion then fill the oil seal as follows A Remove the cover from 90 degree elbow B Fill the short pipe to halfway with oil Note To drain the oil open the plug in 180 degree elbow 4 4 2 2 8 5 inch Water Column Operating Pressure Oil Seal 522 19 69 ITEM DESCRIPTION 500 1 Pipe 1 1 2 inch NPT X 15 50 394 long 2 Pipe 1 1 2 inch NPT X 7 25 184 long 3 135 Sheave elbow 4 135 Sheave elbow with drain E 1 1 2 inch NPT E fd l un HER E 1 E 13 62 346 4 50 90 elbow furnished with Model 2500 mounting kit
101. rated tape can retract up into the conduit where it cannot be reached If you remove the gaugehead secure the end of the tape so it cannot retract up into the conduit Use care to not kink or bend the tape 13 If the gaugehead conduit connector is installed you can now remove the gauge head from the conduit and complete the rest of this disassembly at the workbench 62 Installation and Operations Manual 2500 ATG Gaugehead Disassembly and Re assembly Supporting the gaugehead pull down the cam handles on the coupler and catch the gaugehead as it drops from the conduit Caution Do not release crank handle 7 when negator spring motor is being loaded and thumbscrew lock is removed Item Description Sprocket Sheave Tape Storage Sheave ThumbScrew Lock Tape Keeper Motor Storage Sheave Negator Spring Motor Removable Installation Crank Negator Spring Motor Screw Tape Sheave Pinor Screw Standard Gaugehead with negator spring motor Qo oos amp oN Tape entry for Top Mounted Gauge Tape entry for Side Mounted Gauge o 2 o o 3 o Standard Gaugehead Negator Cassette Gaugehead with negator spring motor shown with negator cassette removed for tape installation Figure 6 2 Tape Routing Varec Inc 63 Gaugehead Disassembly and Re assembly Automatic Tank Gauge 14 15 16 17 18
102. rnished 3 Tape a installation hatch 1 1 2 Inch pipe fittings by customer 4 Tape Cable fastner furnished by customer 5 Pipe Support Bracket 4 50 6 Top Anchor e pe e 7 Bottom Anchor 8 Fa 114 8 Sheave elbow y pa 9 Float Guide Cable wy a 10 Upper support Bracket 11 Deck Flange Unless otherwise noted dimensions in inches millimters All welding by customer View C C Bracket detail 2 51 X 2 51 X 25 6 4 Steel angle Support bracket mounting hardware 1 2 12 furnished by customer 4 50 ar 114 is N Standard i TT roof pitch Hl n 12 1 uii 9 305 n ep B 25 d s ll I gaala Maximumc e il C 36 00 914 ot 7 88 16 00 200 406 Minimum 1 Convenient eye level Grade Figure 3 10 Bolted Cone Roof Tank furnished by customer 1 1 2 Inch NPT pipe nipple Gaugehead Float Tape Tape Cable fastner Pipe Support Bracket Top Anchor Bottom Anchor Sheave elbow Float Guide Cable 10 Upper support Bracket 11 Deck Flange Unless otherwise noted dimensions in inches millimters All welding by customer o60N00 8O9N2 Figure 3 1 I Horizontal Bullet Tank with Roof Reading Gauge nc 21 Installation Automatic Tank Gau
103. rvals with a silicone or Teflon aerosol lubricant such as Penske Car Care Silicone Spray available at most auto parts stores or ZEP 45NC www zep com 7 7 1 Other lubricants recommended for general service Use a low pour point food grade water white mineral oil A few brand names are e ARCO Prime Grade 70 Lyondell DuoPrime 70 Product Code 16402 7 7 2 Other lubricants for service below 25 F 4 C The following lubricants may be used for service below 25 F 4 C Automotive antifreeze and water 50 50 mix Propylene glycol based antifreeze such as Sierra should be considered for environmentally sensitive areas Caution These oils may not be compatible with edible oils and edible liquids Use product compatible substitutes for tanks holding products for human or animal consumption or products that may react chemically with the oil 7 8 Oil filled Gauge Check Caution Gauges measuring caustic liquids require that the gaugehead be oil filled Check that the oil is not leaking and change the oil at regular intervals Dispose of the old oil according to local environmental regulations Oil filling the gaugehead is highly recommended to protect the internal parts from possible corrosion attack by product vapors Oil filling also provides lubrication for the moving parts and could extend service intervals and overall gaugehead life Fill the gaugehead through the top 1 2 NPT plug Approximately 4 75 quarts
104. rvice lille 17 3 InstallallOD curd eke Rune doit pat DEI P aut E uia 19 3 1 Installation Schematics 0 000 ccc eee 20 3 2 Tank Roof Entry Cone Roof Tank 000 cece eee ee 22 3 3 Tank Roof Entry Internal Pan Floating Roof 23 3 4 Tank Roof Entry Stilling Well lille 24 3 5 Correct Float Positioning for an External Floating Pan Installation 25 3 6 Installing Anchors and Guidewires 0 00 cece eee eens 26 3 7 Installing Support Brackets amp Pipework s anaana 0 00 cece eee eae 27 3 8 Installing a Gaugehead at Grade Level 0 000 28 3 9 Installing a Roof Reading Gaugehead 0002 cee eee eee 29 Varec Inc V Automatic Tank Gauge 3 10 3 11 3 12 3 13 3 14 3 15 3 16 3 17 3 18 3 19 3 20 3 21 3 22 4 2 4 3 4 4 45 6 1 6 2 6 3 Float installation on an Out of Service Tank 0000 cece eae 30 3 10 1 Cone Roof Tank 0 00 eee 30 3 10 2 Floating Pan with Floatwell cee eee eee 30 Connecting the Tape to the Float liliis 31 Connecting the Cable to a Float in a Floatwell sus 32 Connecting the Cable to a Floating Pan llle 33 Connecting the Tape to an Interface Float in a 6 Stilling Well 34 Feeding the Tape to a Gaugehead Located at Grade Level 35 Install Tape in the Gaugehead lliisslslellslls lessen 36 3
105. stallation 3 13 Connecting the Cable to a Floating Pan Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Note Due to the resulting gross measurement inaccuracies Varec does not recommend that the perforated tape tape cable be attached directly to a floating pan Use a covered floatwell for the best measurement accuracy Caution Connecting a tape cable directly to a floating pan increases the probability that damage will occur to the tape cable Tearing or snapping of the tape cable could result in dame to the gaugehead 1 If there is no floatwell in the floating roof and no other alternative is available Varec recommends attaching the tape cable to an object that is resting unconnected on the floating roof 2 Refer to the previous section for instructions to cut the cable to the correct length Varec Inc 33 Installation Automatic Tank Gauge 3 14 Connecting the Tape to an Interface Float in a 6 Stilling Well Note Ensure you have completed all previous steps from your installation checklist from section 2 4 before proceeding Note The float guide eyes should be removed cut off whenever it is possible for the 12 13 eyelets to get caught on the sides of the stilling well Using the box that the tape came in pull the tape out like a measuring tape This keeps the tape from becoming twisted or kinked Remove the flange with the
106. the sheave assembly 18 as an assistant provides some tension on the tape to keep it from kinking or twisting 8 Prior to installing the cassette 50 into the gaugehead use the crank assembly 52 to wind the cassette clockwise the number of turns indicated in section 3 16 Install Tape in the Gaugehead on page 36 The counter reading should match the product level 9 Lock the crank assembly by setting the spring loaded screw into the keyhole slot in the cassette 10 With the crank assembly locked in position install the cassette into the gaugehead 11 Install the two socket head screws 49 to secure the cassette to the storage sheave 12 Graspthe crank assembly handle firmly and pull the spring loaded screw to unlock the handle Rotate the handle to take up any slack in the tape 13 Remove the crank assembly 14 Check the tape path to insure that the tape is not twisted or kinked 15 Test the operation of the gauge by rotating the gauge check knob turn clockwise and releasing e The level indicated on the counter should return to the same reading 16 Install the outboard sheave elbow cover 17 Install the back cover and any auxiliary equipment 50 Installation and Operations Manual 2500 ATG In Service Installation Procedures Note The slotted coupling on any auxiliary equipment must engage the drive pin on the sprocket sheave 18 Check the level indication on the gauge and compare it wit
107. tor storage sheave 10 Detach the negator motor 48 from the storage sheave by loosening the securing screw 57 11 Remove the negator motor 48 bushings washers and shims 12 Remove the storage sheave assembly 8 bushings washers and shims 4 1 2 Assembly 4 1 2 1 Install the gaugehead conduit connectors 1 Install female end on the gaugehead and install the male end on the conduit 2 Use pipe thread compound to install the coupler parts Varec Inc 49 In Service Installation Procedures Automatic Tank Gauge 3 Install a Teflon washer if needed 4 a shim washer 45 and the new storage sheave 51 over the lower gaugehead shaft 10 Note In the next step the alignment of the sprocket sheave to the tape storage sheave is critical for proper operation of the gauge 4 Adjust the number of shims to bring the sheaves into the specified alignment as shown on Figure 4 27 0 005 to 0 010 Axial play ee Y XXZYXXI Figure 4 27 Sheave Alignment 5 Complete the installation of the storage sheave by installing shims 45 a Teflon washer if needed 4 and a flat washer 44 6 Test that the sheave turns freely with axial play within 0 005 to 0 010 Lateral off set between the two sheaves should not exceed 0 032 Note If play is excessive add shims 45 to remove play 7 Attach the end of the tape over the sheave pin 28 and while wearing gloves wind the tape onto
108. tric 13 08768 Extended Maintenance Kit Imperial page 78 13 08769 Extended Maintenance Kit Metric 13 08770 Overhaul Refurbishing Kit Imperial page 81 13 08771 Overhaul Refurbishing Kit Metric 13 09794 00 Shoulder Bushing Retrofit Kit page 84 13 10652 Negator Cassette and Kit page 85 13 10100 Gaugehead Conduit Connection Kit page 86 13 10974 Float Grounding Kit page 86 8 1 Gaugehead Spare Parts Table 8 2 2500 ATG Gaugehead Spare Parts Item Part Description B4396 071 Back Cover Gasket Cast gaugehead 02 04490 071 Back Cover Gasket 2 B5059 071 Back Cover Cap Gasket 3 B5060 001 Back Cover Cap 4 B7415 093 Teflon Washer 5 B8235 040 Imperial Dial Gear 5m B8327 040 Metric Dial Gear 6 B7720 071 Counter Cover Gasket 7 B8218 001 Imperial Dial Fractional or Decimal innage 7m B8325 001 Metric Dial innage 8 BA7761 Tape Storage Sheave Assembly Includes items 55x2 57 amp 58 9 B8234 001 Dial Retainer 10 B7693 005 Shaft 2 11 BA17597 Counter Shaft Assembly 12 B10221 093 Seal 13 P34 4 Knob 14 BA14055 Gauge Check Assembly includes items 61 amp 62 15 B7796 005 Spring 16 B6547 005 Tape Keeper Post 17 02 04488 Back Cover 18 06 08558 Imperial Sprocket Sheave Assembly 18m 06 08559 Metric Sprocket Sheave Assembly Varec Inc 73 Spare Parts and Maintenance Kits Automatic Tank Gauge
109. urface of the liquid slowly rotate the crank clockwise while watching the display When the counters stop do not continue to crank Note If the tape becomes slack with the float on the surface the tape may slip off the elbow pulley the tape storage sheave or the tape keeper If this occurs refer to Troubleshooting 3 Turn the crank counter clockwise to raise the float about 2 inches 51 mm above the product then lower it back to the surface The float should not be left on the surface of products that are agitated Raise it to the tank top in this situation and latch the ratchet pawl Varec nc 59 Operation Automatic Tank Gauge 60 Installation and Operations Manual 2500 ATG Gaugehead Disassembly and Re assembly 6 Gaugehead Disassembly and Re assembly Use of the maintenance kits requires that the user understand the disassembly and reassembly of the gaugehead to replace parts 6 1 Gaugehead Disassembly Figure 6 1 below is key to understanding the disassembly reassembly procedure The small numbers in parentheses for example 12 refer to the item numbers in this figure References in the following procedures are directed to this figure unless otherwise indicated 19 includes 9 parts 53 amp 54 TS 7 Note Use washers 44 and 45 as required Not shown 49 51 52 59 20 48 includes parts 55 x2 amp 56 N 5 8 includes parts 3 A 55 x2
110. verhaul The overhaul maintenance kit provides all the recommended parts that may need to be replaced during such a procedure Follow the disassembly instructions in Chapter 6 when replacing any parts on the gaugehead 7 13 General Inspection It is recommended that the you schedule the first inspection after the unit has been in service for the end of the first thirty day period Subsequent inspections should be made every 90 days The user may adjust the schedule for his own convenience and safety depending upon the product Varec maintenance service contracts are available Please consult a sales or service representative for further details 72 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits Spare Parts and Maintenance Kits Varec can supply individual spare parts for the 2500 ATG maintenance kits and installation accessories The following kits are specifically designed to assist with a regular schedule of maintenance and to improve the quality and performance of your 2500 ATG This chapter details the contents of each kit and provides an illustration to assist in locating the part within the assembly Refer to the Maintenance Procedures Disassembly and Assembly before performing any maintenance on the gaugehead Table 8 1 Maintenance Kits Part Description See page 13 08766 Basic Maintenance Kit Imperial page 76 13 08767 Basic Maintenance Kit Me
111. wn 61 06 05 152 005 Gauge Check 62 B7795 005 Gauge Check Spring 65 P109 18 010 Thread Protector not shown 66 16 08843 Label not shown 67 P30 100 Gaugehead Connector male end 68 P30 105 Conduit Connector female end 69 13 10100 Gaugehead Conduit Connection Kit items 67 amp 68 74 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits 19 includes parts 53 amp uS Note Use washers 44 and 45 as required Not shown 49 51 52 59 ED 45 a 48 includes parts 55 x2 amp 56 8 includes parts 55 x2 57 amp 58 Figure 8 4 2500 ATG Gaugehead spare parts Varec In 75 Spare Parts and Maintenance Kits Automatic Tank Gauge 8 2 Basic Maintenance Kit The Basic Maintenance Kit provides all the parts required for basic maintenance on the 2500 ATG Depending on your selection you will receive the metric or imperial parts required Note Use items 44 and 45 as required Figure 8 5 2500 ATG Basic Maintenance Kit Parts 76 Installation and Operations Manual 2500 ATG Spare Parts and Maintenance Kits Table 8 3 Basic Maintenance Kits and Parts Numbers Part No Description 13 08766 Basic Maintenance Kit Imperial 13 08767 Basic Maintenance Kit Metric Item Part No Description Quantity in kit B4396 071 Ba
112. y welding the supplied brackets If the environment is such that welding cannot be performed the user can construct a support structure with 3 inch 76 mm pipe or conduit close to the outside of the tank The brackets can be welded to the support structure at another location if necessary and the pipe structure assembled at the tank site 2 3 4 1 Conduit Elbows Conduit elbows reduce wear on the tape and provide various installation options depending on the tank type Varec can provide various angles materials and low high pressure options 2 3 4 2 Conduit Oil Seals Oil seals designed into the conduit pipework during installation can help reduce wear and maintenance on the tape conduit and gaugehead parts The seals also prevent the loss of damaging fumes or corrosive vapors Figure 2 5 Conduit oil seals Varec nc General Preparation Automatic Tank Gauge 2 3 5 2 3 6 Tank Roof Entry via Manhole amp Inspection Covers Varec highly recommends a manhole or inspection cover be installed for ease of installation and maintenance of the float tape and guidewires Tape conduit and guidewire anchor entries into the tank roof should be near an existing manhole cover within arms reach or be made through a manhole cover If this is not the case install a manhole or inspection hatch A manhole cover Model 226 allows for in service installation of the 2500 ATG through a tank s exist
113. you have completed all previous steps from your installation checklist from section 2 4 before proceeding Using the box that the tape came in pull the tape out like a measuring tape This keeps the tape from becoming twisted or l kinked 2 Figure 3 17 Feed the tape into the tank 2 At the elbow on the tank entry pipe unroll one or two turns of the perforated tape and start to feed it into the tank If your installation is a roof reading application with the gaugehead installed on the conduit on the roof feed the tape through the back of the gaugehead first Continue to unroll it several turns at a time until it reaches the bottom of the tank Let several more inches fall on the tank bottom Cut a 6 inch 152 mm piece of tape from the end inside of the tank Form a U with this piece of tape so there is no hole in the bottom portion of the U Do not kink Grounding Cable N Float Grounding Clamp eg Tape Grounding Clamp A Clamp screw Tape ES 2 required a Tape Clamp e 2 required Cable Gauging Tape formed into U Cable Clamp Avoid bending at hole Tape connector Locking Tube d 6 00 Inch 155 piece of tape formed into a U Avoid bending at hole i i uS 8 DRE MERERI omnc DENT Float Float with ground connector without ground connector Figure 3

Varec 2500 Automatic Tank Gauge Service Manual

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