Technical Manual - Honeywell€¦ · LOG3840 deck digital indicator displays locally the level, temperatures, pressure measured by transmitters. It is powered by the TA3840S safety

Barge System

OPTILEVEL

Technical Manual

SAS au Capital de 2 158 244 € - 444 871 933 R.C.S. Bourges - APE : 2651B

Headquarter : 9, rue Isaac Newton - 18000 Bourges - France

Barge System Technical Manual

OPTILEVEL

1st Edition Released February 2013

INTRODUCTION This manual is issued specifically for the OPTILEVEL system. It contains instructions detailed for functioning and operation of this system.

To use it in an optimal way, we advise you TO READ CAREFULLY THESE INSTRUCTIONS and to respect them throughout the life of the equipment.

Keep this manual to hand so that you can refer to it at any time. Ensure that it is complete and kept close to the equipment.

The OPTILEVEL HLS 6010 probe, OPTILEVEL Supply, T901-P transmitter and LOG3840 indicator are integrated in the system for processing the barges/inland vessels liquid cargo. This system is intended for professional use, it must be used by operators who are qualified and well-versed in the operating rules and safety instructions set out in this manual.

We also draw your attention to the fact that the connection of equipments or the use of products other than those recommended by Honeywell Marine may present risks for which we will not be liable.

This manual must not be reproduced in any form whatsoever without the prior written approval of Honeywell Marine who cannot be held responsible for any use of the information contained in this manual.

As we want you to take advantage of the most of the latest technology and new equipment, as well as to benefit from our experience, our equipments may undergo technical or design changes. As a result, some of the features and information in this manual may change without prior notice and without any obligation to up-date it.

Pictures of this document are not contractual. Should you encounter any problems or have any questions about your EMx40 system,

please do not hesitate to contact your nearest Honeywell Marine customer service.

Other documents The description and operation of the racks TA3840C/R and TA3840S for measuring data collection are described in the MT5008E technical manual.

SAFETY PRECAUTIONS: Current regulations and legislation applicable to hazardous areas must imperatively be known and followed by personnel responsible for commissioning and operating intrinsically safe equipment.

Take care to switch the power off before proceeding to any disconnection or removal of the transmitters.

WARNING:

Our equipments are designed and manufactured in accordance with local safety regulations, and in particular European directives relative to reconciling member states' legislation:

● 89/336/EEC and 2004/108/EC "Electromagnetic compatibility",

● ATEX 94/9/EC "Equipment and protective systems intended for use in potentially explosive atmospheres",

● 96/98/EC "Marine equipment". The OPTILEVEL HLS 6010 / OPTILEVEL Supply and associated transmitters are certified for use in hazardous area according to the intrinsic safety protection type. Examination certificates are supplied in appendix. They are intended for professional use and must be installed, used and maintained by competent staffs that are qualified in this type of equipment. In particular we wish to draw your attention to the fact that we cannot be held responsible if:

● Any technical alterations are made to our appliances without our written authorisation,

● Our equipments are damaged by being operated in conditions other than the intended usage of their technical classification (power supply, temperature, environment, etc.).

The safety instructions given in this manual are merely given for guidance purposes to protect you and all those using and working on our equipments. Honeywell Marine cannot foresee all dangerous situations that might arise. This is why the owner and/or the operator is responsible for the operating safety of the system. Regulations of the ship classification society may impose procedures (health and safety, fire prevention, handling of hazardous substances, etc.) which are stricter than those given in this manual. In this case, the regulations must be followed.

TABLE OF CONTENTS

1. GENERAL DESCRIPTION ............................................................................................................... 6

2. OPTILEVEL HLS 6010 probe ........................................................................................................... 7

3. OPTILEVEL Supply .......................................................................................................................... 8

4. INSTALLATION ................................................................................................................................ 8

4.1 Potential equalization .................................................................................................................. 8

4.2 Ex-technical information HLS 6010 probe ................................................................................... 9

4.3 Ex-technical information OPTILEVEL Supply ............................................................................ 10

4.4 Laying the cables ...................................................................................................................... 11

4.5 Installation of the probe ............................................................................................................. 11

4.6 Connection of OPTILEVEL Supply ............................................................................................ 15

5. START-UP ..................................................................................................................................... 18

5.1 Preparations ............................................................................................................................. 18

5.2 Start Terminal program (Configuration) ..................................................................................... 18

5.3 Assign address / product (tank) ................................................................................................ 19

6. COMMUNICATION ........................................................................................................................ 20

6.1 Communication settings ............................................................................................................ 20

6.2 Commands for installation and service...................................................................................... 20

6.3 Standard commands ................................................................................................................. 21

6.4 Structure of $-Commands ......................................................................................................... 21

7. CERTIFICATES / APPROVALS ..................................................................................................... 23

7.1 Probe HLS 6010 ....................................................................................................................... 23

7.2 Optilevel Supply ........................................................................................................................ 25

Doc No: MT5025E – Revision 3 – ENG TRANSMITTERS OPTILEVEL Technical Manual 6

1. GENERAL DESCRIPTION

Pressure sensor

24 Vdc + RS232 / RS485 / RS422

RS232 / RS485

TA3840C

TA3840R

LOG3840 (optional)

T901-PxxC

RS232 / RS485 / RS422

+24 Vdc power supply

230 / 115 Vac 50 / 60 Hz Power supply

Up to 96 4-20 mA inputs or On / Off inputs or On / Off outputs

Up to 3 temperature sensors and 1 inert gas pressure sensor

Special applications

Configuration software

Monitoring computer

Loading computer

Monitoring computer when fitted with CPU board, as option

3 dry contact outputs: - data alarm, - system fault, - power supply failure.

OPTILEVEL HLS 6010 gauge

or

OPTILEVEL Supply


System description The OPTILEVEL HLS 6010 probe, OPTILEVEL Supply, T901-P temperature/pressure transmitters and LOG3840 deck digital indicator are parts of the OPTILEVEL system, dedicated to monitor the Barges/Inland vessels liquid cargo parameters such as level, temperature and pressure, as well as all associated measurements. They are installed in hazardous area.

The OPTILEVEL HLS 6010 probe measure the liquid level inside the tank and the temperature and transmit the information to the TA3840C communication unit by means of the OPTILEVEL Supply located in Safe area.

The T901-P temperature / pressure transmitters measure the liquid cargo temperature (if more than 1 temperature is requested) and the inert gas pressure. Each T901-P transmitter is directly connected to TA3840C analogue input board. (Already Marine certified).

The LOG3840 deck digital indicator displays locally the level, temperatures, pressure measured by transmitters. It is powered by the TA3840S safety unit and communicates on a RS485 bus. (Already Marine certified).

General synopsis The general synopsis of the system is shown on the previous page. TA3840C, TA3840S, TA3840R T901-P and LOG3840 are part of EMx40 system (see MI5016, MT5016 & MM5016).

2. OPTILEVEL HLS 6010 probe

The probe consists of the head housing with the electronics, a screw thread to fasten it to the tank and the measuring tube. The measuring tube varies in length depending on the tank height.

Important ordering information: To produce a probe we always need the following information: LL = Tank height LG = Probe length

Standard lengths (in mm): Tank height. (LL) Probe length (LG) Segment length

1600 2100 160 2000 2500 205 2500 3000 260 2900 3400 305 3000 3500 317

Special lengths (minimum/maximum lengths in mm): Tank height. (LL) Probe length (LG) Segment length

600 800 51 5800 6000 629


3. OPTILEVEL Supply

The OPTILEVEL Supply provides the power to the connected probes. Depending on the number of probes to be connected there are different versions available.

Up to 4 Supplies can be operated parallely, so that a maximum number of 32 probes can be connected. Superior systems can be connected to the RS232 standard interface.

At the same time the Supply takes over the galvanic separation of each individual probe and offers thereby a safe explosion prevention.

4. INSTALLATION

4.1 Potential equalization As the intrinsically safe circuit is operationally earthed, a common potential equalisation must be provided within the intrinsically safe circuit (within and outside the explosion hazardous area).

The probe must be connected to the same potential equalisation (earthing) as the tank. See also paragraph:

3.6.1. “Connect the 4 mm² cable for potential equalisation to the ground clamp on the housing and link it to the tank lid”

Galvanic separation by OPTILEVEL Supply: The Level Sensor (HLS 6010) is galvanically separated by the ex-barrier (OPTILEVEL Supply). The shield of the connection cable must be connected to the probe head (housing) and to the „E“ terminal clamp on the Supply.

Installation regulations: The earthing of the tank, its cables, etc., resides with the installation engineer or the planning office and is normally examined and adjusted on-site.

The probe’s earthing must also be connected to the tank.


4.2 Ex-technical information HLS 6010 probe Ex-Classification

II 1/2 G Ex ia IIB T4 Ga/Gb

SEV 09 ATEX 0109 IECEx SEV 10.0002 Rating data Supply and signal circuit Ignition protection type intrinsic safety Ex ia IIB

Only for connection to an acknowledged intrinsically safe circuit.

Maximum values:

Ui ≤ 15,9 V

Ii ≤ 250 mA

Pi ≤ 1,2 W

Ci = 210 nF Li is neglectably small

The supply and signal circuits are operationally earthed.

Remarks ● The tank level probe type HLS 6010 belongs to equipment of group II, category 1/2 G

according to regulation 94/9/EG (ATEX 95) Appendix I, and can - according to RL 99/92/EG (ATEX 137) - be used in danger areas 0/1 or 0/2 as well as in gas groups IIA and IIB which are potentially explosive by flammable substances within temperature classes T1 to T4. The requirements according to EN 60079-14 must be adhered to during use and installation.

● The approved environmental temperature range is –20°C to +60°C.

Special conditions X None

Type label


4.3 Ex-technical information OPTILEVEL Supply

Ex - Classification

II (1) G [Ex ia Ga] IIB

EPL (Ga) TÜV 98 ATEX 1382

Rating data The approved environmental temperature range is –20°C to +60°C for the OPTILEVEL Supply and –20°C to +70°C for the OPTILEVEL Supply TA.

Supply circuit (Terminal clamps PH, N)

U = 230V AC, +-10%, 50Hz, Umax 253V

Output and signal circuit(s) (Terminal clamps +, -, Shd) Maximum values per circuit

Ignition protection type intrinsic safety Ex ia IIB Uo = 14.3 V Io = 221 mA P = 1.2 W R = 190 Ω Characteristic curve trapeze-shaped Active inner capacitance: 145 nF The active inner inductances are neglectable small. Maximum permissible outer inductance: 1 mH Maximum permissible outer capacitance: 562 nF

RS232 interface: (Terminal clamps RXD, TXD, GND)

+-15 V

Interface circuit Master-Slave (Terminal clamps In, Out)

5V

The output and signal circuits are galvanically separated from the non-intrinsically safe circuits up to a crest voltage of 375V.

Special conditions X None

Type label


4.4 Laying the cables General Use screened blue polyurethane cable (3x0, 75 mm²) with a diameter of 5 – 9 mm, which is resistant to oil and petrol products and has a maximum length of 250 meters.

4.5 Installation of the probe Preconditions Þ All cables are laid

Þ A G1½ -inch or NPT female thread has been installed on the dome cover

Procedure 1. Wind Teflon tape or hemp yarn around the nipple of the compression fitting

2 Untighten the compression fitting gland of the probe (2 x 60mm jaw spanners) are required

3 Slide the compression fitting down to the welding points and tighten it slightly

4 Place the probe in the tank and tighten the nipple

5 Untighten the PVC gland

6 Place the probe on the bottom of the tank

7 Put the sensor adjusting tool on the dome lid and move the slide upwards to the lower edge of the sensor head. Block the slide with the fixing screw

8 Lift the probe slightly and remove the sensor adjusting tool

9 Move the slide of the sensor adjusting tool 10 mm upwards and block it again by means of the fixing screw

THESE CABLES MUST BE LAID SEPARATELY, i.e. they must be isolated from power cables. The valid high voltage current regulations must be observed!

CABLE CAPACITY: Please note that the cable capacity together with the probe’s inner capacity Ci must not exceed the maximum outer capacity of the Supply (562nF).

NEVER LEAVE A CABLE END IN THE LIQUID! Due to the capillary effect the liquid might penetrate the cable and cause a short circuit.


10 Place the sensor adjusting tool back on the dome lid in the same position as before

11 Lower the probe until the lower edge of the probe head rests on the slide again

12 Tighten the compression fitting of the HLS 6010. (Working thoroughly will ensure that the probe end will be placed exactly 10 mm above the bottom of the tank)

To guarantee the density of the installation the compression fitting must be tightened to 70Nm min.

Taking a spanner with 500mm length equals a weight of 15 kg!

13 Write down the tank number and medium on the test report (will be needed for commissioning). Mention on the test report if the probe cannot be mounted in parallel to the tank axis


4.5.1 Dimensions LPG gauge (in mm)

4.5.2 Electrical connection

4.5.3 Laying the cables 1. Connect the 4 mm² cable for potential equalization to the ground clamp on the housing and

link it to the tank lid 2. Remove the housing lid of the probe head 3. Untighten the PG gland 4. Skin the probe cable and provide it with cable end sleeves 5. Guide the probe cable through the PG gland 6. Tighten the PG gland until the rubber seal forms a small bulge 7. This cable gland meets the tightness requirements according to IP 66/67, i.e. among others

that if the probe is immersed permanently into water, no water may penetrate the electronics. Therefore, this work must be carried out with utmost care!

CAUTION! The screening of the probe cable must be provided with an insulating hose. Wire or cable residuals must not remain in the probe head!


4.5.4 Connection of power supply and signals 1 Connect the grounding braid in the housing lid to

a free „E“- terminal clamp on the electronics.

2 Connect the probe cable to the terminal clamps on the head electronics

The screening of the probe cable is connected directly to the second „E“- terminal clamp or the additional screw in the head housing!

4.5.5 Close probe head housing lid

1. Start by tightening screws 1 and 3 slightly. 2. Then, tighten screws 2 and 4 slightly. 3. Check if the housing lid fits the bottom

parallel. 4. Tighten screws 1 and 3 completely. 5. Tighten screws 2 and 4 completely. 6. Note down tank, product and mechanics

number (important for probe initialisation).

CAUTION! The probe head housing lid must be tightened cross-wisely so that thightness according to ip66/67 is guaranteed.

Probe head with grounding braid

1

1

Electronics with terminal clamps


4.6 Connection of OPTILEVEL Supply

4.6.1 Variants Variant 1 (Stand alone) This variant is used if a Supply is used without OPTILEVEL Controller.

Variant 2 (Slave)

Master and Slave are mounted next to each other (mounting version 1). If there is not enough space Master and Slave can also be mounted above each other (mounting version 2).

4.6.2 Mounting 1. Open the upper lid of the Supply

The picture at the bottom shows a Supply 8. The Supplies 1, 4 and 5 are the same size, but there are less channels assembled.

2. Fasten OPTILEVEL Supply to the wall with 4 screws.

ATTENTION! ELECTROSTATICALLY CHARGEABLE COMPONENTS! Reduce electrostatic charge before touching the board. There might be tension on the solder points of the transformers that have not been

The OPTILEVEL supply must be mounted outside the ex area!


Key: A Blind cover on connection hole F Terminal clamp RS232 B Fixing holes G Terminal clamp Master / Slave C Fixing holes for lid H Blind cover on connection hole for further Supplies D Terminal clamp for connection of power supply I Cable gland E Control light power supply K Terminal clamps for probes 1 Separate power supply for each probe 2 Opto coupler for galvanic separation

Up to 8 probes can be connected to the Supply in any order. However, we recommend you connect the probe of tank no. 1 to the first connector, the probe of tank no. 2 to the second connector, a.s.o. This will help you identify the probes in case of any error.


4.6.3 Connection plan


5. START-UP Terminal program: You may configure the probe with a terminal program using the corresponding commands. This procedure is described on the following pages

5.1 Preparations General: Connect your PC to the Supply via serial interface

Requirements: PC with a Terminal program (e.g. Hyperterminal, OC Console) Connection cable for the serial interface to OPTILEVEL Supply:

RS 232 terminal

Supply Laptop (9-pole D-Sub) RES Reserve GND GND (Pin 5) RxD TxD (Pin 3) TxD RxD (Pin 2)

Make sure that you have the probe mechanics number, the medium as well as the tank number at hand.

5.2 Start Terminal program (Configuration) 1. Start the Terminal program

2. Baud rate: 9600 (standard with delivery)

3. Parity: N (none)

4. Data bits: 8

5. Stop bits: 1

6. Port: depends on the port that is used

7. no handshake

8. local echo on


5.3 Assign address / product (tank) In order to allow the interpreting device to communicate with the single probes, a unique address must be allocated to each probe

We recommend you use the tank number as the probe’s address, so that each probe can be assigned clearly to a tank. Should you wish to assign different probe and tank numbers, you must create a thorough documentation!

Communication with the probes is effected by certain commands. The assignment of probe address and product is carried out by entering the command:

*A <probe number> ↵1. All other commands are described separately in chapter 5.

5.3.1 Entries via Terminal program

Monitor:

Enter the probe’s ID number (can be found on type label). In this example it is: 282055.

A probe address will be requested. Enter a number (two digits). Normally, the tank number is used.

The probe will confirm your entry. The probe address is 01.

Specify the product which will be in the tank. This entry helps the probe to reach a relatively high accuracy immediately after switch-on and before adjusting itself to the new medium.

Remarks: - Enter 4 (Diesel) if the medium is unknown - Enter 8 for products with an Er

2- value > 3, such as

water, AdBlue, E85 The probe will confirm you entry.

Done!

1 „↵“ = <CR> or <Enter> or <Return>

2 „Er“ stands for εr = dielectric constant

Commands


6. COMMUNICATION

6.1 Communication settings General Check if the following settings have been made:

Baud rate: depending on probe settings (see footnote) Parity: N (none) Data bits: 8 Stop bits: 1 COM Port: depends on the port used Local echo: on

6.2 Commands for installation and service

1 Please note: after having changed the baud rate you must also change the baud rate of the terminal program. 2 bbbb: baud rate (300 baud (= default), 1200, 2400, 4800, 9600 or 19200 baud)

Command Answer Description Syntax Syntax Description Set address and medium *A< probe ID ><CR> Dialogue Set address and medium in

dialogue. Change baud rate1 *B<adr>bbbb2 ><CR> <Value><CR> Confirmation H-protocol (description see page 37)

*J<adr><Value<CR> <Values> Fill level data transferred to POS system.

Set medium *M<adr> Selection list Set medium in dialogue with probe

Set Offset (absolute) *O<adr><Value><CR> #0<Value><CR>

Internal Offset <Value>=Offset [mm]

Replace *R<ID> Electronics><CR>

Dialogue Adjustment of electronics, offset and reprogramming of wet and dry values.

Dry value adjustment *U<ID> Electronics><CR> Dialogue HF Upgrade

Offset adjustment *Y<adr<Value><CR> #Value Enter the value of a manual dip-stick reading. The probe will then calculate a new offset value and adjust the old value.

Request service data $S<adr><CR> Text Service data Request service data in English

$I<adr><CR> Text Service data in English

Request extended service data $E<adr><CR> Text Service data extended

Special command (usually used if you are not sure about a probe’s address)

$S99<CD> Text Each probe connected will reply to this command. Therefore, only one probe must be connected when carrying out this command.


6.3 Standard commands

Command Answer Description Syntax Syntax Description Retrieve all level values $A<adr><CR> <Values><CR> Command for Controller3

Retrieve all volume values $B<adr><CR> <Values><CR> Volume command with strapping table on probe only

Retrieve all ullage values $C<adr><CR> <Values><CR> Ullage command with strapping table on probe only

Retrieve water level $G<adr><CR> #=<Value><CR> Water level in mm

Retrieve temperature $T<adr><CR> #[±]<Value><CR> Temperature in °C/10

Retrieve fill level $V<adr><CR> #0<Value><CR> Fill level in mm

6.4 Structure of $-Commands 6.4.1 $A-Command

6.4.2 $B-Command Syntax (ASCII-characters) Range of values (ASCII-characters) Description

#< Value > @< Value > @[±]< Value > @[±]< Value > @< Value > @< Value > @< Value > <CR>

0..999999 0..9999 000..999 0..9999 00..999 0..9 00.. FF

Volume in litres Water level in mm Temperature in °C/10 Probe offset in mm Software version Probe error Checksum

3 Not used

Syntax (ASCII-characters) Range of values (ASCII-characters) Description

#0<Value> @< Value > @[±]< Value > @[±]< Value > @< Value > @< Value > @< Value > <CR>

0..99999 0..9999 000..999 0..9999 00..999 0..9 00.. FF

Fill level in mm/10 Water level in mm Temperature in °C/10 Probe offset in mm Software version Probe error Checksum


6.4.3 $C-Command

*¹ Sensor errors 1 Wrong DIP Switch settings (only for old 5-segment and 9+1 probes) 2 No connection to EEPROM 3 No electronics adjustment done (usually carried out by Hectronic) 4 No dry and wet value adjustment done (usually carried out by Hectronic) 5 A field adjustment is being carried out (only with old HF Industry Software) 6 Temperature sensor error

The following error message might be displayed in case of an error:

*² Checksum calculation

The checksum is the XOR link of all characters, checksum value and <CR> excluded. The checksum is displayed in HEX.

Syntax (ASCII-characters) Range of values (ASCII-characters) Description

#< Value > @< Value > @[±]< Value > @[±]< Value > @< Value > @< Value > @< Value > <CR>

0..999999 0..9999 000..999 0..9999 00..999 0..9 00.. FF

Ullage in litres Water level in mm Temperature in °C/10 Probe offset in mm Software version Probe error*¹ Checksum*²


7. CERTIFICATES / APPROVALS

7.1 Probe HLS 6010



7.2 Optilevel Supply


Honeywell Marine SAS 9, Rue Isaac Newton 18000 Bourges France Tel + 33 (0) 2 48 23 79 01 Fax + 33 (0) 2 48 23 79 03 E-mail: [email protected] www.honeywellprocess.com

MT5025E-rev03-ENG February 2013 © 2013 Honeywell International Inc.

mailto:[email protected]





Documents

Technical Manual - Honeywell€¦ · LOG3840 deck digital indicator displays locally the level, temperatures, pressure measured by transmitters. It is powered by the TA3840S safety