INSTRUCTION MANUAL

TR-22
ANALOG + ALARM TRANSMITTER FOR TANK GAUGES

IM-L541(4)-1E
APR. 2006

1. SCOPE OF DESCRIPTION
AND RELEVANT MANUALS
This Instruction Manual describes TR-22
type Analog + Alarm transmitter for tank gauges.
TR-22
type Analog + Alarm transmitter is mounted
onto FT-1000 float gauge or onto FP-1000 pipe guided
float tank gauge. The liquid level is converted into
DC4~20mA and alarm contact(s) is (are) obtained at set
points.
Refer to the following separate Instruction Manuals for
such mechanical portion of tank gauges:
Model
FT-1
FP-1

Applicable Instruction Manual

IM-L541
IM-L542

3. OPERATIONAL NOTES
General notes

2. NOTATION RULES
Safety symbols
This manual classifies safety notes using the following
symbols:

If this indication is disregarded and this instrument is operated incorrectly, serious injury or fatal accident may result.

If this indication is disregarded and this instrument is operated incorrectly, injury or property damage may result.

General information symbols

This operation manual classifies general information
notes using the following symbols:

Indicate procedures or information required to operate

this product.

Indicates information that should be understood to enable this product to be operated safely and comfortably.

(-P.

The indicated page contains information other than notes

that should be referenced.

This product is delivered after manufacturing and adjustment. Inspections have been conducted
based on the optimum quality control method for industrial instruments. If any attempt is made to modify or change
this instrument, it may fail to perform as intended, or incompatibility or accidents may result. Do not modify or
change this instrument in any way. If it is necessary to
modify or change it, contact Tokyo Keiso Co.
Be sure to operate the instrument
within the ranges of the specifications for fluid pressure
and temperature listed in the Approval drawing. If the instrument is operated out of these ranges, it may become
defective or be damaged.

During transportation and storage,

ensure to prevent moisture, dirt or sand from entering
the instrument as such will cause damage or render the
instrument defective.

Use this product only as an industrial instrument.

4. PRODUCT OUTLINE, OPERATION

PRINCIPLE, AND PRODUCT
CONSTRUCTION

Material
The material of this product is described in the Approval drawing. Although we make every effort to select the optimal material for the customer's
specifications, it may not be perfect due to the presence
of foreign matter. Thus you are responsible for checking
anticorrosivity and compatibility.

4.1 Product outline

TR-22
type Analog + Alarm transmitter is mounted
onto tank gauges.
The mechanical movement of tank gauge is connected
with transmitter by gear down mechanism. Such mechanical motion of tank gauge is converted into current
signal by potentiometer and electric circuit. Also, the
mechanical movement drives alarm microswitches.
Watertight and flameproof types are available.

Maintenance and inspections

When removing this product from
your process for maintenance or inspection, make sure
there is no object to be measured remaining in the instrument. If the object is corrosive or toxic, the operator may
be adversely affected.

4.2 Operation principle

The movement of float of tank gauge drives its measuring tape and rotates sprocket pulley in indicator housing.
The rotation angle (number of rotation) of the sprocket
pulley corresponds to the length of tape movement which
is finally corresponds to liquid level movement.
TR-22
type Analog + Alarm transmitter is driven
by this rotating movement of sprocket pulley which further drives potentiometer and alarm driving cam.

The frequency and contents of the

maintenance and inspection of this product vary depending on the operational conditions. See the relevant section of this manual or check the actual operational conditions.

Control Safety
This product is delivered after manufacturing, adjustment and inspections have been conducted based on the optimum quality control method for
industrial instruments, but an unexpected critical problem may occur. If this product is used for process control, take all necessary actions to maintain safety.

Operation principle of TR-22

type Analog + Alarm transmitter

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Intrinsically Safe version TR-220S

* Angle convertor
* Link Motion
* Gear down mechanism
Block diabram TR-220-S

4.3 Product construction

TR-22
type Analog + Alarm transmitter consists of:
* Gear down mechanism
* Current output unit
Potentiometer
Current output circuit
* Alarm output unit
* Terminal, terminal box
* AC power circuit (Option)

Angle convertor

Microswitch

Gear down mechanism

Link motion

Cam

Gear down mechanism

Output circuit

Details of specification is as follows:

Level change for one rotation of sprocket pulley
300mm
Used angle converter
YEW EBS Rotation angle 40
Max. load resistance
350
Combination safety barrier
BARD400
Frameproof cerrtificate
EBS angle convertror
TIIS CERT. No. T34322
BARD400 Safety barrier
TIIS CERT. No. T30772

Coupling plate
Potentiometer

Terminal box

Block diagram of
TR-22
type Analog + Alarm transmitter
Details of specification is as follows:
Level change for one rotation of sprocket pulley
300mm
Used Potentiometer
Type CP-6 by Midori Instruments Co.
Rotation angle
240 to 300
Resistance change
0 to 2k
Type of R/I convertor and max. load
Type
TR-220W
DC 24V
AC 100V
TR-220E
DC 24V
AC 100V

Type of R/I convertor

Max load

PM2W (M System)
PM (M System)

400
750

PF-030C (Tokyo Keiso)

PM (M System)

600
750

5. MODEL CODE
Model code of this product is as follows:
TR-22
indicates number of alarm contact.
1
1 point
2
2 points
3
3 points
4
4 points
TR-22

indicates housing construction.

W
Watertight
EX Flameproof construction (JISd2G4, Exd2CT6)
S
Intrinsically safe (i3aG5)*1

Frameproof certificate

*No alarm can be added to IS version.

Type
Power supply Classification Certificate No.
TR-220E DC24V
Exd@CT6
TC16561
d2G4
T37856
AC100V
d2G4
T23669

TR-220

Cable glands with flameproof pressure tight gasket are

optionally provided. indicates this supply.
Blank Thread connection only
B
Cable glands with explosionproof gasket is provided.
(Cable gland is attached for EX version as standard)

Used micrswitch for alarm

Type
VX-5-1A2
Manufacturer
OMRON CO.
Contact capacity
AC250V, 5A
DC125V, 0.4A

Ex version has been approved, assembled with the flameproof equipment. Be sure to use the cable gland of designation of our company.

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6. INSTALLATION

7. WIRING AND ADJUSTMENT

6.1 Installation of total tank gauge with

transmitter (New installation)

7.1 Wiring
7.1.1 DC24V 2-wire transmission type
1) The standard cable entry is G1/2 thread. Other screws
are also available on request. Confirm in Approval
drawing.
2) Conduct wiring as per following figure.
3) The terminal screws is M4. Use compression terminal chips for firm connection.

TR-22
type ANALOG TRANSMITTER is mounted
and delivered onto FT-1
or onto FP-1
tank
gauges.
Refer to Instruction Manual of applicable tank gauge
and conduct Wiring and Adjustment mentioned in 7.

6.2 Additional installation of guage

In case of installation onto existing tank gauge, the rear
cover of subject tank gauge is to be the type of Transmitter Attachable.
These Transmitter Attachable tank gauges are indicated
and identified by the following model codes:
FT-1
2
, FP-1
2

For the additional installation of transmitters onto standard tank gauges, replacement of the rear cover of subject tank gauge is required. Contact Tokyo Keiso for
details of such availability.

Follow the local flameproof regulations for Ex version.

Conduct suitable watertight sealing after completion
of wiring to avoid introduction of rainwater.
The power supply voltage and load resistance are to
be within the specification mentioned in Approval
drawing.
Load/Indicator
DC24V

The procedure of Additional Installation of transmitter

is as follows:
1) Remove the cover of transmitter connection unit.
2) Insert the coupling plate of transmitter into the
mounting hole of rear cover of transmitter. Do not
forget the gasket.
3) The slit of the coupling plate is to match the position
of the pin of the sprocket pulley in tank gauge.
4) The cable entry of terminal box is to be located downward.
5) Mount and fix by using bolts. These bolts are customers' scope of supply.
6) Tighten the bolts equally by using a spanner with
17mm width. (M10 bolts )
7) Mount the cover of transmitter connection unit.
8) In case of Intrinsically safe version (TS-220S-
),
the housing of transmitter has different shape than
other version. However, the installation procedure is
identical.
Pin

Standard wiring diagram

7.1.2 AC Power supply
1) The standard cable entry is G1/2 thread. Other screws
are also available on request. Confirm in Approval
drawing. Two cable entries are provided for AC power
supply and signal transmission. Use separate cable
entrires.
2) Conduct wiring as per following figure.
3) The terminal screws is M4. Use compression terminal chips for firm connection.

Follow the local flameproof regulations for EX version.

Conduct suitable watertight sealing after completion
of wiring to avoid introduction of rainwater.
The power supply voltage and load resistance are to
be within the specification mentioned in Approval
drawing.

Loacal/Indicator

Sprocket pulley
Coupling plate

U
AC Power supply
V
Standard Wiring diagram

Rear cover of tank gauge

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7.2 Wiring of alarm contacts

This adjustment is conducted by opening of housing with
power supply. During opening the housing cover, the flameproof function is lost. Take necessary and proper actions to
meet the local flameproof regulation requirement.

1) Take care not to introduce rainwater from cable entries if wiring is not conducted together with tank
gauge installation
2) The standard cable entry is G1/2. Other threads are
also available. Confirm in the Approval drawing.
3) The terminal arrangement differs in number of alarm
points. It also to be confirmed in Approval drawing.
4) Use suitable compression terminal chips for firm
connection.
5) Conduct watertight sealing after completion of wiring to avoid introduction of rainwater.

Zero Adujustment Potentiometer

Span Adjustment Potentiometer

PF-030C

Follow the local flameproof regulation in case of EX

version.

7.3.2 Confirmation of output

1) By using float hoisting mechanism of tank gauge,
move the float from 0% position to 100% position
and confirm that the output changes from 4mA to
20mA properly.

6) Install specified safety relay in safe area in case of Intrinsically safe version. Follow the local flameproof
regulation. In case that the safety relay is Tokyo Keiso's
scope of supply, detailed dimension, terminal arrangement etc. are shown in Approval drawing.

7.3 Adjustment and confirmation of output

7.3.1 Adjustment and confirmation of analog output
1) Loosen the screw which fix the shaft of potentiometer to gear down mechanism to make the movement of potentiometer shaft free. Rotate the potentiometer shaft to obtain reasonable output current corresponding to local indication.
2) Confirm that the resistance of potentiometer changes
continuously for full span of tank gauge.
3) After completion of course adjustment, tighten the
screw of coupling.

0% Level
Hoisting handle

Gear

Screw

100% Level

Potentiometer

Fine adjustment
1) Zero and Span adjustment Potentiometers are located
on the surface of circuit board PF-030C.
2) By using float hoisting mechanism of tank gauge,
locate the float at 0% position and 100% position.
Then adjust the output by rotating potentiometers.

Hoisting handle

2) When any discrepancy/error is found, check the adjustment of output according to 7.3.1
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8. OPERATION

7.3.3 Adjustment of alarm contact

Adjustment
1) Alarm points have been adjusted and delivered according to the customers' order specification.
2) After completion of indication adjustment of tank
gauge, adjust total cam angle of the shaft. Then, each
setting point will be automatically adjusted.
3) Loosen the screws which fixes the shaft and rotate
shaft to adjust alarm point.

1) The supply voltage and load resistance for analog

output are to be within the specification mentioned
in Approval drawing. Observe the following for alarm
contact output:
Contact capacity and contact protedtion
The contact capacity of standard microswitch is as follows:
AC250V, 5A /DC125V, 0.4A
1) Use within the above capacity.
2) Special versions of microswitch, i.e. gold plated contact, is used on request. Confirm the contact capacity in Approval drawing in such cases.

Cam
Screw
Micro switch
Shaft
Screw

3) Minimum load to standard microswitch is

DC5V,160mA. Smaller load may result conductivity problem. It is recommened to use gold plated contact mircoswitch for these applications.

Shaft

7.3.4 Changing of each setting point

If actuation point of specific contact is needed, loosen
the screw which fixes the specific cam and change the
angle of actuation cam.
7.3.5 Confirmation of actuation point
After completion of setting/adjustment of alarm point,
it is recommended to confirm the alarm actuation by
shifting the float of tank gauge by using hoisting mechanism of tank gauge.

0% Level
Hoisting handle

100% Level

Hoisting handle

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9. MAINTENANCE

9.4.2 For alarm contacts

1) Replace microswitch referring to the following
sketch, if required.
2) Turn off the power supply.
3) Check and confirm the positions of Cam and Actuator.
4) Connect the cables to terminal properly.

9.1 General maintenance items and

recommended intervals
Procedure
Item
Checking of
Visual check
terminal box.
Water rust etc.
Confirmation of
Visual check
cable termination
Confirmation of
Shifting the float
alarm actuation
and confirm
Comparison
Confirmation of
output signal
against local indication

Interval
12 months

Cam
Screw

12 months

Micro switch
Shaft

12 months

Screw

12 months
Shaft

9.2 Troubleshooting
Phenomenon

Suspected cause

Terminal loosening
Cable disconnection

No output
(4mA)

Replacement
Problem of electric circuit
/readjustment

Output
discrepancy
against local
indication

Mechanical error
Electric adjustment
Internal electronics failure

No contact
output

Loosening of cable,
terminal
Cable disconnection
Trouble of microswitch
Loosing of coupling plate
Loosening of
actuation on cam

Contact the following for service and spare parts supply

etc.

Reconnection
Replacement
/repair of cable

No output
(0mA)

Tank gauge
indication
and alarm
actuation
point not
match

10. SERVICE NETWORK

Countermeasure

TOKYO KEISO CO., LTD.,

Overseas Department
Shiba Toho Bldg.,
1-7-24, Shibakoen, Minato-ku, Tokyo, 105-8558.
TEL: 03-3431-1625
FAX: 03-3433-4922
Home page address: http://www.tokyokeiso.co.jp
E-mail address: overseas.sales@tokyokeiso.co.jp

Check and readjust

Readjustment
Replacement
/readjustment
Re wiring
Repair/
replace of cable
Replacement
Checking and
readjust
Checking and
readjust

11. PRODUCT WARRANTY

Unless otherwise stipulated, we offer the following guarantee.
DURATION
18 months after our delivery or 12 months after start-up
whichever comes earlier.

9.3 Spare parts

In case of requirement of spare parts, identify the parts
name and the manufacturing number of subject product.
The manufacturing number of subject product is shown
on Tag plate.
Example of Manufacturing No. L99-12345-6

SCOPE OF WARRANTY:
Any damages incurred by our mistakes in design, manufacture and/or selection of material.
ENFORCEMENT OF WARRANTY
Warranty will be completely by replacement of equivalent
instrument or repair of subject instrument. Tokyo Keiso is
not responsiblel for the secondary losses even if any.

9.4 Parts replacement

9.4.1 For analog output portion
1) Potentiometer type CP-6 and current output circuit
PF-030C are often replaced.
2) Turn off the power supply and follow the local flameproof regulation.
3) Conduct output adjustment properly after the replacement of parts.

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