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Honeywell FlexLine SmartServo 954 Installation Manual Download Page 3

 

 

 

Part No: 4417341 Revision 10   

 

 

Installation Manual                                                                  3 
954 SmartServo FlexLine  

 

 

                       

 

 

 

 

About this manual 

 

This manual provides information related to installation of the 954 SmartServo FlexLine.  

For  servicing  of  the  device  refer  to  the  954  SmartServo  FlexLine  Service  Manual  listed  below  in 
References.  

For Safety instructions and procedures refer to the 954 SmartServo FlexLine Safety manual listed 
below in References.  

 

Introduction 

The 954 SmartServo FlexLines an automatic tank gauge measuring the surface or interface level of 
crude oil or derived products stored in a bulk storage tank. Typically those storage tanks are available 
on  terminals,  production  plants  and  refineries  in  the  petro  chemical,  oil  and  gas  industry.  The 
environment on those sites is typically explosion hazardous.  

The  end  user  will  typically  use  the  954  SmartServo  FlexLine  together  with  a  Terminal  Inventory 
System for custody transfer operations, therefore Weights and Measures legislation is applicable. 

The 954 SmartServo FlexLine is based on the modular FlexConn board architecture. Every FlexConn 
board supported in this device is described in detail. 

 

Revision History 

954 Installation Manual (This document) 

4417341 

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9

th

 November 2018 (1st Release) 

4417341 

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20

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 November 2018 (Updated the document) 

4417341 

02 

22

nd

 November 2018 (Updated the document) 

4417341 

03 

23

rd

 November 2018 (Finalized the document) 

4417341 

04 

29

th

 November 2018 (Added Relay Output Section) 

4417341 

05 

29

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 November 2018 (Updated Pmax on Relay Output) 

4417341 

06 

10

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 December 2018 (Updated pages 21 and 32) 

4417341 

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10

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 January 2019 (Added FM information on page 16) 

4417341 

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17

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 January 2019 (Added temperature range on page 16) 

4417341 

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23

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 January 2019 (Added I/O text to tables on page 35, 36, 38 & 39) 

4417341 

10 

12

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 March 2019 (Added CSA information on page 16) 

 

Summary of Contents for FlexLine SmartServo 954

Page 1: ...Installation Manual 954 SmartServo FlexLine ...

Page 2: ...ne For service related questions contact Head Office Delft The Netherlands Honeywell Enraf Delftechpark 39 2628 XJ Delft PO Box 812 2600 AV Delft The Netherlands Tel 31 0 15 2701 100 Fax 31 0 15 2701 111 E mail HFS TAC Support Honeywell com Website www honeywellprocess com ...

Page 3: ...ally use the 954 SmartServo FlexLine together with a Terminal Inventory System for custody transfer operations therefore Weights and Measures legislation is applicable The 954 SmartServo FlexLine is based on the modular FlexConn board architecture Every FlexConn board supported in this device is described in detail Revision History 954 Installation Manual This document 4417341 00 9th November 2018...

Page 4: ...y contain information relevant to the information in this document 4417340 1 954 Service Manual 4417342 1 954 Safety Manual Patents The Honeywell 954 SmartServo FlexLine servo based level gauge is covered by the following patents US2017307461 A1 2017 10 26 US2018058960 A1 2018 03 01 WO2017062413 A1 2017 04 13 WO2018044518 A1 2018 03 18 ...

Page 5: ...structions 10 2 3 1 Safety Instructions 10 2 3 2 EC Declaration of Conformity for EU 10 2 3 3 Control Drawings for FM CSA 10 2 3 4 Users 10 2 3 5 Additional Information 10 2 3 6 Environmental Conditions 10 Liability 11 Labels 11 Personal Safety 12 Warnings and Cautions 12 2 7 1 General 12 General Precautions 14 Accordance to Regulations 15 2 9 1 Explosion Safety 15 3 PRINCIPAL OF SERVO MEASUREMENT...

Page 6: ...CAL INSTALLATION 23 General 23 Grounding 23 Safety 24 5 3 1 General Relative Density 24 Installing the Cable Glands and Stopping Plugs 25 5 4 1 Cable Glands 25 5 4 2 Unused Cable Inlets 25 Installing the Glands Conduits and Stopping Plugs 26 5 5 1 Conduits 26 5 5 2 Unused Cable Inlets 26 Electrical Connections 27 5 6 1 Grounding 27 5 6 2 Connections 27 Finishing Installation 39 5 7 1 Assembling th...

Page 7: ...um 15 Figure 4 Principle of Measurement 17 Figure 5 Orientation of the Gauge on a Tank top view 20 Figure 6 Mounting a Pressure Gauge Set on a 954 SmartServo FlexLine Gauge 22 Figure 7 Example of Flange Ground 22 Figure 8 Optional Blocking Devices 24 Figure 9 954 SmartServo FlexLine Board Overview 29 Figure 10 Intrinsically Safe and Non Intrinsically Safe Cable Entries 30 Figure 11 Wiring Connecti...

Page 8: ...variety of industry standard protocols RelatedDocuments 954 SmartServo FlexLine Safety instructions for installation commissioning operation and maintenance shipped with the device CE Declaration of Conformity EC Type Examination Certificate IEC Ex Certificate of Conformity Control drawings for FM and CSA Trademarks HART is a registered trademark of the HART Communication Foundation Contact Head O...

Page 9: ...all personnel follow the generally accepted safety procedures in addition to the safety precautions specified in this manual SafetyConventions WARNINGS The following warning symbol is used in this manual to urge attention in order to prevent personal injuries or dangerous situations further described in this manual Symbol Description Remark General warning Will always be explained by text CAUTIONS...

Page 10: ...ained personnel with knowledge of the requirements for installation of explosion proof equipment in hazardous areas The entire installation procedure must be carried out in accordance with national local and company regulations The entire electrical installation shall be carried out in accordance with the national requirements for electrical equipment to be installed in hazardous areas NOTE See EN...

Page 11: ...ents descriptions and specifications in this Installation Manual are subject to change without notice Honeywell accepts no responsibility for any errors that may appear in this Installation Manual WARNING Only certified technicians are authorized to make changes on the 954 SmartServo FlexLine configuration All modifications must be in accordance to the guidelines as set forth by Honeywell Modifica...

Page 12: ...detection equipment WarningsandCautions 2 7 1 General Opening of the Instrument WARNING DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE MAY BE PRESENT When it is required to open the instrument in an explosive hazardous environment take care of the following WARNING Make sure that the power to the device is switched off before you open the covers of the device Failure to do so may cause danger to persons...

Page 13: ...e explosion proof tools for example testing devices WorkingEnvironment Hazardous Area WARNING Potential Electrostatic Charging Hazard Avoid generation of static electricity Safe Area WARNING Avoid generation of static electricity Make sure no explosive gas mixtures are build up in the working area Required Skills WARNING The technician must be trained and qualified to safely install equipment in h...

Page 14: ...al 14 954 SmartServo FlexLine GeneralPrecautions CAUTION During transport of the gauge the motor block should be locked This is for protection of the weighing system Motor Locked Motor Unlocked Figure 2 Unlocking the 954 SmartServo FlexLine Motor ...

Page 15: ... qualified commissioning engineer Accurate measurement requires an undamaged and clean drum Figure 3 Measuring Drum Special Tools Screw driver for Hex Allen key screws M4 length min 22 mm Tommy bar Accordanceto Regulations 2 9 1 ExplosionSafety ATEX II 1 2 G Ex db h IIB T6 Ga Gb or II 1 2 G Ex db eb h IIB T6 Ga Gb or II 1 2 G Ex db h ia Ga IIB T6 Ga Gb or II 1 2 G Ex db eb h ia Ga IIB T6 Ga Certif...

Page 16: ...db h ia Ga IIB T6 Ga Gb or Ex db eb h ia Ga IIB T6 Ga Gb Certificate no IECEX IECEx DEK 18 0033 X IP66 67 FM XP Class I Division 1 Group C D T6 AIS Class I Division 1 Group C D Ta 40 C to 65 C NEMA 4X Certificate no FM19US0012 CSA Class I Division 1 Group C D Ex db eb h ia Ga IIB T6 Ga Gb Ta 40 C to 65 C Encl 4 Certificate no 70210644 ...

Page 17: ...ong flexible measuring wire which is stored on a precisely grooved measuring drum The shaft of the drum is connected to the stepper motor via a magnetic coupling The apparent weight of the displacer is measured by a force transducer The actual output of the force transducer is compared with a desired value for the apparent weight of the displacer If a discrepancy exists between measured and desire...

Page 18: ... one step is equivalent to 0 05 mm This resolution is a direct consequence of the stepper motor principle The correct functioning of the stepper motor is continuously checked This is achieved by decoding the unique pattern of an encoder disk mounted on the motor shaft 3 1 2 InterfacebetweentwoProducts Measurement of the interface between two products is achieved by sending an interface command to ...

Page 19: ...NG Verify that tank or drum compartment is depressurized before opening the tank or drum compartment cover of 954 SmartServo FlexLine The 954 SmartServo FlexLine can be adapted to various process connection flanges via adapters calibration chambers as specified in Appendix B Verify that maximum working pressure of adapter calibration chamber complies with pressure in your tank WARNING 954 SmartSer...

Page 20: ...uge in one of the following two ways Figure 5 Orientation of the Gauge on a Tank top view On a stilling well or guide pole the orientation of the gauge may be chosen freely NOTE The weight of the 954 SmartServo FlexLine for medium pressure version is 16 kg 35 lbs chemical version is 21 kg 46 lbs high pressure version is 26 kg 57 lbs ...

Page 21: ...MountingaPressureGaugeSet 1 Connect T piece horizontally to drum house 2 Check whether manometer is suitable for the maximum pressure in the tank 3 Mount manometer and vent valve Figure 6 4 Close vent valve 5 Gently open valve between tank and drum compartment and check for leakage on all connections Flange type Number of bolts Diameter x minimum length NW50 ND6 4 M12 x 50 NW50 ND40 4 M16 x 60 2 1...

Page 22: ...ng of the 954 SmartServo FlexLine install a copper strip under one of the flange bolts for each flange Place shark rings between flange and strip Figure 7 Figure 7 Example of Flange Ground NOTE Also in case of tanks with cathodic protection the 954 SmartServo FlexLine must be grounded to the tank Cathodic protection can be maintained by isolating the cable screen armouring or conduit ...

Page 23: ...be sealed within 18 inches of the enclosure Improper installation of cable glands conduits or stopping plugs invalidates the Ex approval of this device Make sure that the housing of the device is properly bonded to the Protective Earth PE WARNING Cables and cable glands for at least 105 C 221 F shall be used When the ambient temperature is known to be always less than 50 C 122 F cables and cable g...

Page 24: ... damage the thread of the covers and instrument and keep the thread free of dirt After opening grease it lightly with anti seize grease When closing never tighten the covers before the threads are properly engaged The covers should be turned counter clockwise until the thread clicks in place then turn clockwise until the covers are fully closed After closing the covers do not forget to place the b...

Page 25: ...ls of an appropriate IP value CAUTION Improper installation of cable glands or stopping plugs will invalidate the Ex approval of the 954 SmartServo FlexLine 5 4 1 CableGlands Use Ex e or Ex d 3 4 NPT cable glands or where applicable equivalent conduit connections with an appropriate IP value See the type plate on the device NOTE Install the cable glands according to the instructions provided by th...

Page 26: ...e explosion proof Ex d conduits with an appropriate IP value See the type plate on the device WARNING If the 954 SmartServo FlexLine is installed in a hazardous area Metal conduits must be used size 3 4 Stopper boxes must be installed within 45 cm 18 of the device to seal the cabling in the conduit NOTE Install the conduits according to the instructions provided by the manufacturer 5 5 2 UnusedCab...

Page 27: ... on proper grounding Check the resistance of the ground connection directly after installation The measured ground resistance must be below the maximum prescribed by local and or national grounding requirements 5 6 2 Connections WARNING The intrinsically safe options have been certified for use in hazardous areas Make sure that the certificate of approval is available on site and act in accordance...

Page 28: ...ically safe connections The indices of the terminals are variable They are specified in a label attached in front of the terminal row as is schematically indicated in Figure 11 General Procedure Connect the wiring to the terminals with the numbers as shown in the tables in the following sections 954 SmartServo FlexLine Board Overview CAN Servo CAN PSS CAN HART and CAN LCD boards are part of each 9...

Page 29: ...d Overview Non intrinsically Safe Connections The non intrinsically safe connections are connected to the grey wiring terminal If local and or national regulations allow the power supply Enraf fieldbus and hardware relay outputs may be combined into one unshielded cable A separate cable may also be used for each ...

Page 30: ... FlexLine is divided into a non intrinsically safe and an intrinsically safe part Cable entries are NPT Figure 10 Intrinsically Safe and Non Intrinsically Safe Cable Entries The non intrinsically safe cabling may only enter at the two right hand side cable entries Figure 10 WARNING The Instrument may not be opened when an explosive atmosphere may be present ...

Page 31: ...well Enraf field bus lines may share one cable Mind the isolation voltage of the cores in the cable refer to the International Standard IEC 61010 1 NOTE If a quad cable is used and all four cores are twisted together use two opposite cores for Honeywell Enraf field bus lines and the two others for mains Terminal information Solid stranded 0 5 6 1 5 4 Flexible stranded wire with end 0 5 4 0 5 2 5 T...

Page 32: ...eaker as disconnecting device and shall disconnect all current carrying conductors Cable Specifications Label Parameters 00 Vin a L 24 65 Vdc 15 10 65 240 Vac 15 10 50 60 Hz 10 Automatic selection 01 Vin b N Enraf Fieldbus Bi Phase Mark CAN BPM Cable specifications Type Twisted pair Rmax 200 Ohm line Cmax 1 μF Maximum length 10 km Cable specifications Type Suitable for the 954 SmartServo FlexLine ...

Page 33: ...he terminal labels are programmed during commissioning Cable specifications Type 18 AWG minimum with shielded twisted pair with max 8 multi drop Gauge connections Maximum length 4 km Label Parameters 06 or 08 TL1 4800 bps 07 or 09 TL2 Cable specifications Type Approved for use in hazardous areas and suitable for the specified power rating Label Parameters 14 Ry1_a Vmax 125 Vac Imax 0 5 A via doubl...

Page 34: ... AO COM and 52 AO ACT Label Parameters 18 Ry3_a Vmax 150 Vac Imax 3 A Vmax 40 Vdc Imax 3 A Pmax 450 W NO NC by factory jumper 19 Ry3_b 20 Ry4_a Vmax 150 Vac Imax 3 A Vmax 40 Vdc Imax 3 A Pmax 450 W NO NC by factory jumper 21 Ry4_b Label Parameters 50 AO PAS Iin Iout 1 24 mA Vin Vout 10 24 5 V 51 AO COM 52 AO ACT Label Parameters 54 DO1_a Vmax 250 Vac Imax 2 A Vmax 40 Vdc Imax 2 A Pmax 500 W 55 DO1...

Page 35: ... water bottom measurement Cable specifications Type Shielded twisted pair Maximum length 1200 meter Label Parameters 46 or 48 4 20 mA Iloop 0 to 25 mA 47 or 49 4 20 mA Vmax 55 Volts Cable specifications Type Twisted pair shielded Rmax 25 Ω line Maximum length 1000 meter Label Parameters 22 V_Loop Ex ia IIB The I O shall not be accessible or shall be isolated in the end use Uo 23 1 V Ensure the end...

Page 36: ...pair shielded Rmax 25 Ω line Maximum length 1000 meter Label Parameters 24 V_Loop Ex ia IIB The I O shall not be accessible or shall be isolated in the end use Uo 23 1 V Ensure the end user cannot touch these wires when energized Io 124 mA Po 0 6 W Co 1 0 μF Lo 9 mH 25 GND_Loop Cable specifications Type Twisted pair shielded Rmax 25 Ω line Maximum length 1000 meter Label 954 SmartServo FlexLine Pa...

Page 37: ...opology Terminals for HART and VITO are combined A maximum of 4 HART devices or 2 HART devices if VITO is present can be connected to the HART connection CAUTION Before connecting the HART devices Make sure the sum of the start up currents fits the parameters Figure 12 Topology ...

Page 38: ...vision 10 Installation Manual 38 954 SmartServo FlexLine RTD MRT MPT Temperature Measurement CAN RTD RTD 4 Wire Connection RTD 3 Wire Connection Cable specifications Type Shielded Rmax 100 Ω line Maximum length 150 meter ...

Page 39: ...1 AssemblingtheTerminalBlockandBoardCompartment sLids WARNING Make sure the surface of the O ring grooves of the housing are clean and the O rings are not damaged before assembling the lids to the 954 SmartServo FlexLine housing Make sure that the both lids used for terminal block and board compartments do not squeeze any cables during the assembly NOTE If existing installations have terminals 22 ...

Page 40: ...arking on the identification label of the 954 SmartServo FlexLine to determine which type of cable glands is required NOTE Mount the glands according to the supplier s instructions Conduit If the 954 SmartServo FlexLine is installed in a hazardous area threaded rigid metal conduit or threaded steel intermediate metal conduit shall be used NOTE If the 954 SmartServo FlexLine is installed in a hazar...

Page 41: ...ounding requirement Grounding can be performed by copper strips across the flanges refer to section Grounding at mechanical installation or by a ground wire With last mentioned method use one of the external ground terminals of the 954 SmartServo FlexLine NOTE Grounding shall be performed in accordance with local regulations CAUTION Safety depends on proper grounding Check the resistance of the gr...

Page 42: ...ndixA Dimensions 954 SmartServo FlexLine Medium Pressure and Chemical Version a Position of measuring wire with displacer in top position b 200 mm 7 7 8 space needed to remove cover c 65 mm 2 9 16 space needed to remove measuring drum d 100 mm 4 free space for SmartView Connection ...

Page 43: ...endixA Continuation Dimensions 954 SmartServo FlexLine High Pressure Version a Position of measuring wire with displacer in top position b 200 mm 7 7 8 space needed to remove cover c 65 mm 2 9 16 space needed to remove measuring drum d 100 mm 4 free space for SmartView Connection ...

Page 44: ...Part No 4417341 Revision 10 Installation Manual 44 954 SmartServo FlexLine AppendixB Available Adapters Calibration Chambers ...

Page 45: ...otoprint microfilm or any other means without the written permission from Honeywell For more information To learn more about SmartLine Transmitters visit www honeywellprocess com Or contact your Honeywell Account Manager Process Solutions Honeywell 1250 W Sam Houston Pkwy S Houston USA TX 77042 Honeywell Control Systems Ltd Honeywell House Skimped Hill Lane Bracknell England RG12 1EB 4417341 Rev 1...

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