Service Manual 954 SmartServo FlexLine - Honeywell Process

Service Manual

954 SmartServo FlexLine

E661590

Stamp

GENERAL

ii Service Manual Part No.: 4417340 Revision 1 954 SmartServo FlexLine

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: [email protected] Website: www.honeywellprocess.com

GENERAL

Part No.: 4417340 Revision 1 Service Manual iii 954 SmartServo FlexLine

About this manual

This manual is a detailed how to reference for servicing the 954 SmartServo FlexLine.

For installing, wiring, configuring, starting up, operating, maintaining and calibrating refer to the 954 SmartServo FlexLine Installation guide 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 FlexLine is 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, so 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 Service Manual (This document)

4417340 1.0 March 2019 (1st Release)

References

The following list identifies publications that may contain information relevant to the information in this document.

4417341 1 954 SmartServo FlexLine Installation Guide 4417342 1 954 SmartServo FlexLine Safety Manual

GENERAL

iv Service Manual Part No.: 4417340 Revision 1 954 SmartServo FlexLine

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

GENERAL

Part No.: 4417340 Revision 1 Service Manual v 954 SmartServo FlexLine

Table of Contents

1 GENERAL ............................................................................................................................................. 1

1.1 Target Group for this Service Manual .................................................................................................... 1

1.2 Structure of this Manual ........................................................................................................................ 1

1.3 Trademarks ............................................................................................................................................ 1

2 SAFETY AND SECURITY ......................................................................................................................... 2

2.1 General .................................................................................................................................................. 2

2.2 Safety Conventions ................................................................................................................................ 2 WARNINGS ........................................................................................................................................ 2 Cautions ............................................................................................................................................ 2

2.3 Safety Instructions ................................................................................................................................. 3 Safety Instructions ............................................................................................................................ 3 EC Declaration of Conformity (for EU) .............................................................................................. 3 Control Drawings for FM & CSA ........................................................................................................ 3 Users ................................................................................................................................................. 3 Additional Information ..................................................................................................................... 3 Environmental Conditions ................................................................................................................. 3

2.4 Liability .................................................................................................................................................. 4

2.5 Labels .................................................................................................................................................... 4

2.6 Personal Safety ...................................................................................................................................... 5

2.7 Warnings and Cautions ......................................................................................................................... 5 General.............................................................................................................................................. 5

2.8 Commissioning and Maintenance ......................................................................................................... 6

2.9 Accordance to Regulations .................................................................................................................... 7 Explosion Safety ................................................................................................................................ 7 Low-Voltage Directive ....................................................................................................................... 8

2.10 Security Considerations ......................................................................................................................... 9

3 PRINCIPAL OF SERVO MEASUREMENT ................................................................................................. 12

3.1 Principle of measurement ................................................................................................................... 12 Level measurement ........................................................................................................................ 13 Interface between two products .................................................................................................... 13 Relative density ............................................................................................................................... 13

3.2 Servo gauges ....................................................................................................................................... 14

4 SYSTEM ARCHITECTURE ...................................................................................................................... 16

4.1 954 SmartServo FlexLine Architecture ................................................................................................. 16

4.2 FlexConn Modules ............................................................................................................................... 17

GENERAL

vi Service Manual Part No.: 4417340 Revision 1 954 SmartServo FlexLine

4.3 Entities ................................................................................................................................................. 22 Status Entities .................................................................................................................................. 22 Generic Entity ................................................................................................................................. 24 Function-specific Entities ................................................................................................................ 24

4.4 HART SmartView Display ..................................................................................................................... 25 General ........................................................................................................................................... 25 Status Entities on HART SmartView ................................................................................................. 26 Generic Entities on HART SmartView .............................................................................................. 27 Specific Entities on HART SmartView .............................................................................................. 27

4.5 Engauge Service Tool ........................................................................................................................... 28 Status Entities in Engauge ............................................................................................................... 29 Generic Entities in Engauge ............................................................................................................ 29 Board-specific Entities in Engauge .................................................................................................. 29 Specific Entities on Engauge ............................................................................................................ 29 Function-generic Entities on Engauge ............................................................................................. 29

5 SERVICE TOOLS ................................................................................................................................... 30

5.1 HART SmartView ................................................................................................................................. 30 General ........................................................................................................................................... 30 HART SmartView Versions ............................................................................................................... 30 Connections .................................................................................................................................... 30 HART SmartView Controls ............................................................................................................... 31 HART SmartView Menu Structure ................................................................................................... 33

5.2 Engauge .............................................................................................................................................. 47 Connecting the Engauge Service Tool .............................................................................................. 47 Using Engauge ................................................................................................................................. 48

6 INSTALLATION .................................................................................................................................... 49

7 COMMISSIONING ................................................................................................................................ 50

7.1 Checks before starting the commissioning .......................................................................................... 50

7.2 Installation of measuring drum and displacer..................................................................................... 51 Tools ................................................................................................................................................ 51 Installation of measuring drum ...................................................................................................... 53 Installation of displacer ................................................................................................................... 54 Unlocking (locking) the motor block ............................................................................................... 55

7.3 Configuring FlexConn boards .............................................................................................................. 56 Introduction .................................................................................................................................... 56 Text Conventions ............................................................................................................................ 57 Enraf Fieldbus (HCI-BPM) ................................................................................................................ 58 Product Level Measurement (TII-SRV) ............................................................................................ 61 Miscellaneous ................................................................................................................................. 97 Relay contacts (FII-DO) ................................................................................................................... 98 FCI-HRT, HART master .................................................................................................................. 108

GENERAL

Part No.: 4417340 Revision 1 Service Manual vii 954 SmartServo FlexLine

Average Temperature Measurement (FII-RTD) ............................................................................ 136 HART Analog Outputs (HCI-HAO) .................................................................................................. 148

TRL/2 Fieldbus (HCI-TRL) ............................................................................................................... 159 Integrated display (TII-LCD) .......................................................................................................... 188 SIL overfill and underfill protection (FII-SIL) ................................................................................. 213 Errors ............................................................................................................................................ 214 Commissioning .............................................................................................................................. 219 Proof Testing ................................................................................................................................. 219 Entities .......................................................................................................................................... 219

7.4 Configuring the servo gauge ............................................................................................................. 231

7.5 Alarm settings ................................................................................................................................... 232

7.6 Level calibration ................................................................................................................................ 233 Standard level calibration ............................................................................................................. 233 Level calibration with a tank top reference stop .......................................................................... 233 Level calibration using the top of ball valve ................................................................................. 234 Interface measurement ................................................................................................................ 235

7.7 Advanced configuration .................................................................................................................... 237 Set point compensations .............................................................................................................. 237 Level compensations .................................................................................................................... 239 Protection and detection settings ................................................................................................ 245

8 OPERATION ...................................................................................................................................... 247

8.1 Repeatability test .............................................................................................................................. 247

8.2 Lock test ............................................................................................................................................ 247

8.3 Freeze and block commands ............................................................................................................. 247

8.4 Unlock................................................................................................................................................ 248

8.5 Interface measurement ..................................................................................................................... 249

8.6 Dip mode ........................................................................................................................................... 249

8.7 Servo Auto Test ................................................................................................................................. 250

8.8 Verify level calibration ....................................................................................................................... 253 Verify level calibration against a tank top reference stop ............................................................ 253 Verify level calibration on top of ball valve .................................................................................. 254

9 MAINTENANCE ................................................................................................................................. 255

9.1 Preventive maintenance .................................................................................................................... 255 Check bearings command ............................................................................................................. 256 Measure displacer weight ............................................................................................................. 257 Balance test .................................................................................................................................. 258 Run-down test .............................................................................................................................. 261 Repeatability test (refer to section 8.1) ........................................................................................ 263

9.2 Instrument covers .............................................................................................................................. 263

GENERAL

viii Service Manual Part No.: 4417340 Revision 1 954 SmartServo FlexLine

9.3 Drum compartment ........................................................................................................................... 263 Removing the measuring drum .................................................................................................... 265 Replacing the drum bearings ........................................................................................................ 266

9.4 The electronic compartment ............................................................................................................. 267 Detailed description ...................................................................................................................... 267 Dismantling the electronic compartment ..................................................................................... 268

9.5 Calibrating force transducer .............................................................................................................. 271

9.6 Synchronizing the reference encoder ................................................................................................ 275

10 954 Density option ............................................................................................................................ 276

10.1 Introduction ....................................................................................................................................... 276 Functional description .................................................................................................................. 276 Principle of operation ................................................................................................................... 277

10.2 Commissioning .................................................................................................................................. 277 Installation on the tank ................................................................................................................. 277 Calibration of the 954 level gauge ................................................................................................ 277 Setting of density items ................................................................................................................ 278 Settings for a tank profile measurement (command Tank profile) .............................................. 279 Settings for an interface profile measurement (command Interface profile) .............................. 280 Corrections.................................................................................................................................... 281

10.3 Operation .......................................................................................................................................... 281 Manual input ................................................................................................................................ 281 Data items, commands and error codes ....................................................................................... 281

10.4 Maintenance and trouble shooting ................................................................................................... 282 Maintenance ................................................................................................................................. 282 Trouble shooting ........................................................................................................................... 282

11 TROUBLE SHOOTING ......................................................................................................................... 284

11.1 Problems with displacer movement .................................................................................................. 284

11.2 Status Codes ...................................................................................................................................... 284 Informational status codes ........................................................................................................... 285 Warnings ....................................................................................................................................... 286 Errors ............................................................................................................................................ 287

12 Appendix A: Article and part numbers ............................................................................................... 290

13 Appendix B: Additional information on displacers ............................................................................. 293

14 Appendix C: ASCII table ..................................................................................................................... 295

GENERAL

Part No.: 4417340 Revision 1 Service Manual 1 954 SmartServo FlexLine

1 GENERAL

1.1 Target Group for this Service Manual The 954 SmartServo FlexLine Service Manual is intended for service engineers who are assigned to commission the 954 SmartServo FlexLine.

1.2 Structure of this Manual Chapter Title Description 1 - GENERAL This chapter provides the introductory information for the

manual.

2 – SAFETY & SECURITY This chapter provides all the essential and mandatory safety instructions, precautions, and measures. It also describes the safety conventions used, the labelling information, and the compliance information.

3 – PRINCIPAL OF SERVO MEASUREMENT

This chapter provides the basic principles of servo based measuring system.

4 - SYSTEM ARCHITECTURE

This chapter provides an introductory impression of the 954 SmartServo FlexLine’s modular-shaped hardware architecture.

5 - SERVICE TOOLS This chapter provides the description of the SmartView and the Engauge service tool.

6 - INSTALLATION This chapter provides a reference to the Installation Guide for the 954 SmartServo FlexLine to make sure the relevant module(s) are accurately installed, before starting the commissioning.

7 - COMMISSIONING This chapter provides the information required for an accurate commissioning of one or more 954 SmartServo FlexConn modules.

8 - OPERATION This chapter describes the basic operation of the 954 SmartServo FlexLine.

9 - MAINTENANCE This chapter provides tests that can be executed for preventive maintenance and procedures for physical part replacement.

10 – DENSITY OPTION This chapter provides the information required to perform density measurements.

11 TROUBLESHOOTING This chapter provides descriptions for the diagnostic data and procedure for testing and checking if the displacer is running freely.

1.3 Trademarks

HART® is a registered trademark of the HART Communication Foundation.

SAFETY AND SECURITY

2 Service Manual Part No.: 4417340 Revision 1 954 SmartServo FlexLine

2 SAFETY AND SECURITY

2.1 General

The 954 SmartServo FlexLine is a servo-based level gauge which is used in inventory measurement systems. It can also be used to interface with other systems and sensors such as pressure, density, or temperature sensors.

For the correct and safe servicing of this product, it is essential that all personnel follow the generally accepted safety procedures in addition to the safety precautions specified in this manual.

2.2 Safety Conventions

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

The following caution mark is used in this manual to urge attention in order to prevent damages to the equipment further described in this manual.

Symbol Description Remark

General caution sign

SAFETY AND SECURITY


2.3 Safety Instructions

Safety Instructions See the safety instructions shipped with the device for installation, commissioning, operation, and maintenance.

EC Declaration of Conformity (for EU)

Refer to the EC declaration of conformity shipped with the device.

Control Drawings for FM & CSA

Refer to the control drawings shipped with the device.

Users The mechanical and electrical installation must be carried out only by trained 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.

Additional Information

If you require additional information, contact Honeywell or its representative.

Environmental Conditions Observe the environmental conditions for the temperature and the pressure.

SAFETY AND SECURITY


2.4 Liability The information in this installation guide is the copyright property of Honeywell. Honeywell disclaims any responsibility for personal injury or damage to equipment caused by:

Deviation from any of the prescribed procedures,

Execution of activities that are not prescribed,

Neglect of the safety regulations for handling tools and use of electricity.

The contents, descriptions and specifications in this Service Manual are subject to change without notice. Honeywell accepts no responsibility for any errors that may appear in this Service 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. Modifications not authorized by Honeywell will invalidate the approval certificates.

2.5 Labels

NOTE: This is a conceptual view of the type plate and therefore subject to change.

FIGURE 2-1 Identification label with Safety note on the SmartServo FlexLine

NOTE: Labels are exemplary and subject to change.

SAFETY AND SECURITY


2.6 Personal Safety

WARNING! National, local and company regulations regarding personal safety must be followed. Pay attention to the kind of product in the tank. If there is any danger for your health, wear a gas mask and take all the necessary precautions.

WARNING! Take appropriate precautions when chemical or toxic product

vapours are present (compressed air, chemical protection suit, and detection equipment).

2.7 Warnings and Cautions

General

2.7.1.1 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 or damage the equipment. All covers of the device must be closed before switching the power on again.

WARNING! Treat the flange surface of the cover and the housing with care. Keep the flange surface free of dirt. The O-ring must be present and undamaged.

2.7.1.2 Tools

WARNING! Use non-sparking tools and explosion-proof testers. Use suitable explosion-proof tools (for example, testing devices)!

SAFETY AND SECURITY


2.7.1.3 Working Environment 2.7.1.3.1 Hazardous Area

WARNING! Potential Electrostatic Charging Hazard!

Avoid generation of static electricity.

2.7.1.3.2 Safe Area WARNING! Avoid generation of static electricity. Make sure no explosive

gas mixtures are build up in the working area.

2.7.1.4 Required Skills

WARNING! The technician must be trained and qualified to safely install equipment in hazardous areas. The technician must work in accordance with national, local and company regulations.

2.8 Commissioning and Maintenance

• 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.

• All wiring entries must be closed such that the approvals are not invalidated. See the see the Installation Guide for the 954 SmartServo FlexLine, to make sure that the correct thread type is selected. For installations using cable glands, use Ex d compound barrier glands. For installations using conduits, each conduit must be sealed within 18 inches of the enclosure.

• Make sure that the housing of the device is properly bonded to the Protective Earth (PE).

SAFETY AND SECURITY


2.9 Accordance to Regulations

Explosion Safety

• ATEX

o SmartServo FlexLine II 1/2 G Ex d IIB T6 or Ex d [ia] IIB T6 according to KEMA 07ATEX0010 X

• IECEx

o SmartServo FlexLine without Integrated (HART) HART SmartView Zone 0/1 Ex d IIB T6 or Ex d [ia] IIB T6 according to IECEx KEM 07.0003X

• FM

o SmartServo FlexLine Class I, Division 1, Groups C and D, T6, according to 3030575

• CSA

o SmartServo FlexLine Class I, Division 1, Groups C and D, T6, Enclosure 4X, Dual Seal Ex d [ia Ga] IIB T6 IP66 / IP67 Ga/Gb, according to 1921040

SAFETY AND SECURITY


2.9.1.1 IC (Industry Canada)

Industry Canada Statement: This device complies with RSS-210 of the Industry Canada Rules. Operation is subject to the following two conditions:

1. This device may not cause interference and

2. This device must accept any interference, including interference that may cause undesired operation of the device.

This class B digital apparatus complies with Canadian ICES-003

Cet appareil est conforme à la norme CNR-210 des règlements d'Industrie Canada. Son fonctionnement est sujet aux deux conditions suivantes:

1. Cet appareil ne doit pas provoquer d'interférences et

2. Cet appareil doit accepter toutes les interférences, y compris celles pouvant entraîner son dysfonctionnement.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

NOTE: This device is certified to measure liquid levels in metal, concrete or similar materials, enclosed tanks

NOTE: The radiated output power of the device is far below the exposure limits. Nevertheless, use the device in such a manner that the potential for human contact during normal operation is minimal.

Low-Voltage Directive The device is suitable for the following:

• Pollution degree 2

• Overvoltage category II

• Class I equipment

SAFETY AND SECURITY


2.10 Security Considerations The 954 SmartServo FlexLine provides several features designed to prevent accidental changes to the device configuration or calibration data.

These features include:

• Configuration Lock protection of HART SmartView local commissioning tool and display

• Configuration Lock protection for every communication interface • Hardware W&M write protect jumper / switch per FlexConn board • Hardware full configuration write protect jumper / switch per FlexConn

board • Hardware Configuration Lock read protect jumper / switch • Software W&M write protect seal

A hardware write-protect jumper / switches locks out W&M / all changes regardless of the entry of a Configuration Lock. The hardware jumper requires physical access to the device as well as partial disassembly and should not be modified where the electronics are exposed to harsh conditions or where unsafe conditions exist.

For W&M configuration changes without changing the W&M hardware jumper position the accredited service engineer or notified body representative may choose to rely on the software W&M write protect seal.

A tamper detection feature is available for the CAN-SERVO (TII-SRV) main control module of the 954 SmartServo FlexLine that can indicate that an attempt was made to change either the configuration or calibration of the device. This security features is designed to avoid accidental changes and to provide a means to detect if an attempt was made to change the configuration or upgrade the firmware when (W&M) sealed and when the device is completely sealed.

• W&M Tamper attempts (last 10 attempts Date & Time) • W&M Tamper counter • Device Tamper attempts (last 10 attempts: Date & Time) • Device Tamper counter

SAFETY AND SECURITY


Security note 1

During commissioning the hardware full configuration write protect jumper / switch for each FlexConn board should be placed so no unintended or accidental configuration changes will be possible.

For security and unintended changes by people that are not allowed making changes the "Protect all configuration jumper" must be placed on all boards after device commissioning and a physical seal shall be applied to the outsight of the device.

Put the "Protect all configuration entities" jumper of all relevant boards so no external resource can modify anything of the configuration (operational settings) of the 954 SmartServo FlexLine.

Security note 2

During (at a last step of the) commissioning the hardware W&M write protect jumper / switch should be placed so no unintended or accidental metrology configuration changes will be possible.

Security note 3

During commissioning the default Configuration Locks should be changed at first use.

Board Default Configuration Lock

CAN-BPM (HCI-BPM) ENRAF2

CAN-HART (FCI-HRT) AAAAAA

CAN-TRL2 (HCI-TRL) ENRAF2

CAN-HART-SLAVE (HCI-HAO) ENRAF2

During (at a last step of the) commissioning the hardware Configuration lock read protect jumper / switch should be placed so the changed Configuration Locks could not be read out anymore.

SAFETY AND SECURITY


Security note 4

After commissioning the 954 SmartServo FlexLine enclosure should be physically sealed.

By having the physical seals applied the boards are not directly accessible to remove the hardware configuration protection jumpers.

In case the physical seals are removed tamper is detected by visual inspection which will be interpreted as fraud from a legal perspective.

How to report a security vulnerability

For the purpose of submission, a security vulnerability is defined as a software defect or weakness that can be exploited to reduce the operational or security capabilities of the software or device.

Honeywell investigates all reports of security vulnerabilities affecting Honeywell products and services.

To report potential security vulnerability against any Honeywell product, please follow the instructions at:

https://honeywell.com/pages/vulnerabilityreporting.aspx

Submit the requested information to Honeywell using one of the following methods:

Send an email to [email protected].

or

Contact your local Honeywell Process Solutions Customer Contact Centre (CCC) or Honeywell Technical Assistance Centre (TAC) listed in the “Support and Contact information” section of this document.

PRINCIPAL OF SERVO MEASUREMENT


3 PRINCIPAL OF SERVO MEASUREMENT 3.1 Principle of measurement

Figure 3-1 Principle of measurement

The principle is based on detection of variations in the buoyancy of a displacer. The displacer is suspended from a strong, 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 desired value, an advanced software control module adjusts the position of the stepper motor.



Level measurement A level variation of product, in which the displacer is partially immersed, causes a change in buoyancy, which will be detected by the force transducer. The resulting difference between measured and desired value will cause a variation in the position of the stepper motor and consequently raise or lower the position of the displacer until the measured value equals the desired value.

To avoid oscillations, a certain hysteresis and integration time is software adjustable. This results in a stable and accurate averaged level measurement.

The stepper motor turns one revolution for every 10 mm of vertical movement of the displacer.

One revolution is divided into 200 steps, therefore one step is equivalent to 0.05 mm. This resolution is 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.

Interface between two products Measurement of the interface between two products is achieved by sending an interface command to the gauge. This causes the stepper motor processor to move the displacer to a position where the apparent weight of the displacer matches a pre-programmed set point.

Relative density To measure the relative density, the displacer is positioned at specific heights and the apparent weight of the displacer at each height is measured. Knowing the volume of the displacer, its weight in air, and the measured apparent weight, the relative density of the product at each position of the displacer can be calculated. The software for the density measurement is available as an option.



3.2 Servo gauges Servo tank gauges (Figure 3-2) are a considerable improvement over the float driven instruments. They were developed during the1950s. In this gauge, the float is replaced by a small displacer, suspended by a strong, flexible measuring wire. Instead of a spring-motor, servo gauges use an electrical servo motor to raise and lower the displacer. An ingenious weighing system continuously measures the weight and buoyancy of the displacer and controls the servo system. The motor also drives the integral transmitter. Mechanical friction in the servo system, transmitter, local indicator and alarm switches has no effect on the sensitivity and accuracy of the gauge. Also, turbulence has no direct effect. An integrator in the serve control system eliminates the effects of sudden product movements. The gauge not only produces an average level measurement under turbulent conditions, but it also eliminates unnecessary movements and reduces wear and tear, greatly extending the operational life of the instrument.

Figure 3-2 Servo gauge



The original servo gauge does not look much like today's modern version. The instruments have evolved into highly reliable mature products, and are gradually replacing mechanical float gauges, cutting down on maintenance and improving on inventory results. Modern intelligent servo gauge shave very few moving parts, resulting in long term reliability and accuracy. They also have a high degree of data processing power. The instruments do not merely measure the liquid level but are also capable measuring interface levels and product density. Accurate, programmable level alarms are standard. Accuracy's of better than 1 mm (1/16 inch) over a 40 m (125 ft) range can be attained. The exceptional accuracy and reliability has resulted in the acceptance of the measurements and remote transmission, by Weights & Measures and Customs & Excise authorities in many countries.

SYSTEM ARCHITECTURE


4 SYSTEM ARCHITECTURE

4.1 954 SmartServo FlexLine Architecture The 954 SmartServo FlexLine system is built up from interchangeable hardware modules. These modules consist of uniform printed circuit boards (PCBs), each of them representing a different, unique functionality. Together with the software implemented on these hardware parts, each PCB makes up a FlexConn module. These modules communicate with each other through the serial CAN-bus on the DIN rail backplane - on which they are mounted. See Figure 4-1

Figure 4-1 954 SmartServo FlexLine system architecture overview

SYSTEM ARCHITECTURE


4.2 FlexConn Modules

One of the main characteristics of the 954 SmartServo FlexLine architecture is its placement flexibility of the FlexConn modules. Any types of modules can be added. Two identical modules can also be placed in the 954 SmartServo FlexLine system.

Each FlexConn module has one or more function. In general, this can be a sensor function, a communication function, or a digital-interface function.

A sensor function measures or calculates a process value, or it obtains a process value from a connected external instrument.

A communication function ensures communication with a communication interface unit or with a DCS, SCADA, tank inventory, or another terminal automation system.

A digital-interface function controls digital output or reads digital input from instruments around the storage tank.

NOTE: Some FlexConn PCBs are also used in the SmartLink system.

Each FlexConn module has a unique name, which is built according to the following image.

Figure 4-2 FlexConn Module

SYSTEM ARCHITECTURE


Each FlexConn PCB consists of a generic and a specific electronic part. The generic part can be found on any FlexConn modules. The specific electronics part represents an application-specific function. See

Figure 4-3.

Figure 4-3 A typical FlexConn PCB layout

The following parts are available on the generic electronics part.

The program memory

This memory contains the module-specific software.

The microprocessor / controller

The microprocessor executes the module-specific software stored in the program memory.

The non-volatile memory

SYSTEM ARCHITECTURE


The commissioning parameters and the diagnostics data are stored when the power is switched off.

Jumpers:

With the jumpers, specific hardware settings can be made:

Jumper Number

Function

1 All warning and monitoring-related commissioning entitiesa are protected and cannot be changed

2 The password is protected from being read

3 All commissioning entities are protected and cannot be changed

4 Board-specific jumper

5 Board-specific jumper a) For an explanation of the entities concept, see section 0

SYSTEM ARCHITECTURE


Entities.

Health LED

The Health LED (= LE1, the blue circle) indicates the general health status of the FlexConn module.

Health Status Flashing Pattern Good

Uncertain

Bad

2 function LEDs

These LEDS indicate module-specific activities, such as for instance data being transmitted or received.

SYSTEM ARCHITECTURE


3 voltage monitors

The output of these monitors, being voltage levels from three different FlexConn PCB locations, are used for diagnostics purposes. See Figure 4-4

Figure 4-4 Locations of the 3 voltage monitors

1 temperature sensor

For the operational PCB, this sensor acts as an input for environmental- temperature diagnostics. The PCB’s environmental temperature is used as a measure for the temperature inside the 954 SmartServo FlexLine.

SYSTEM ARCHITECTURE


4.3 Entities Information exchange between the various FlexConn modules takes place by means of the entities.

An entity represents a unique information association in the FlexConn architecture. This information may consist of measuring data, status data, commissioning parameters, diagnostics data, or commands.

In addition to the information exchange between FlexConn modules, entities are used for data presentation on the HART SmartView display, and for the communication between the Engauge service tool and the 954 SmartServo FlexLine.

The entities are represented by a textual description, for example, “Reset”, “Tank bottom”, “Health”, or “Baudrate”.

The entities structure is related to the following:

General status information

Generic FlexConn part

Function-specific FlexConn part

Status Entities The “Health” and “Commissioned” entities provide information about the general FlexConn module status and the functions implemented on this module.

4.3.1.1 Health Entity

The “Health” entity reflects the condition of the entire module, each single module function, and the calculated or measured value of a sensor function.

The “Health” entity structure is defined by following items:

1. status

2. status category

3. status code

The status field gives high-level information:

good

uncertain

bad

SYSTEM ARCHITECTURE


The following tables provides information about the status code and the specific reason why the status is good, uncertain, or bad. This information is presented as an information number coupled with a textual description of this specific situation.

Good

Uncertain

Bad

actual

manual

last valid

stored

instrument

environment

un-in

it

kille

d

no d

ata

unde

r ran

ge

over

rang

e

hw fa

il

sw fa

il

cal f

ail

001 056 077 104 632 328 207 782 065 478 199 389 011 072 ........................................................

Each board implements “health” as generic information based on the function (s) health(s).

Each function implements “health” as generic information.

Each sensor and digital I/O function implements an entity called “Primary Value”, which in addition to the actual measured value also contains a “health” status.

4.3.1.2 Commissioned Entity

The “Commissioned” entity informs the end user if the most important commissioning entities of the concerned FlexConn module and its implemented functions are set correctly.

True = the most important entities are set correctly

False = the most important entities are not set correctly

SYSTEM ARCHITECTURE


Generic Entity The following command entities are implemented as generic functions.

“Reset device”

“Reset board”

The following information is available through the entities.

“Board name” = FlexConn module name

“Board hardware version” = Hardware version of the FlexConn PCB

“Firmware version” = Version of the software running on the FlexConn module

The firmware (software) version data is built up according to the format below:

A 1 0 0 0 0

internal preliminary

bug fixes

minor functionality

warning + measuring data related part

main functionality

hardware modifications

The last digit is not shown in the official or formal releases.

Function-specific Entities

For the function-specific entities, see section COMMISSIONING 7

SYSTEM ARCHITECTURE


4.4 HART SmartView Display

General

The HART SmartView is used to set and control most of the FlexConn module settings

Figure 4-5 An impression of the HART SmartView

For each sensor and digital I/O function implemented on a FlexConn module, a Primary Value screen is available on the HART SmartView display. In the left bottom quarter of the display, the Primary Value’s “Health” status is displayed.

Status Display Text Good Uncertain uncertain

Bad bad

Below the Status field, the Status category is displayed:

Status Category Display Text actual manual manual

last valid last valid

stored stored

instrument instrument

environment environment

general hardware fail hardware

general firmware fail software

general commissioning fail commission

general calibration fail calibration

general operational fail operational

SYSTEM ARCHITECTURE


Status Category Display Text

over range over range

under range under range

no data available no data

un-initialized no init

killed killed

Status Entities on HART SmartView Select sub-menu “commissioning” from the main menu to view the survey results of all FlexConn modules present in the 954 SmartServo FlexLine system.

Each module is followed by an indication for the “Health” and the “Commissioned” status respectively. In case of an unreliable or fault situation, the “Information” column displays an information code in addition. This information code reveals the specific reason about the current status.

This diagnostic is available for each individual FlexConn module. See example below.

H C I

FII-DO G N

The “Health” indication is as follows:

“G” = Good

“U” = Uncertain

“B” = Bad

The “Commissioned” indication is as follows:

“Y” = the most important entities are set correctly

“N” = the most important entities are not set correctly

Starting from the “commissioned” menu and selecting the specific FlexConn module, the above diagnostics is repeated for each module function. See example below.

FII-DO:>

board H C I

Relay 1 G N Relay 2 G Y Relay 3 U Y nnn Relay 4 B Y

SYSTEM ARCHITECTURE


Generic Entities on HART SmartView From the functions survey screen of the concerning FlexConn module, the generic entity commands or the commissioning entity can be selected through the “board” entry.

FII-DO:>

board H C I

Relay 1 G N

Relay 2 G Y

Relay 3 U Y nnn

Relay 4 B Y

Specific Entities on HART SmartView Selecting a specific function, for instance, “Relay 2”, gives access to the specific entities for this function.

The specific entities are described in section COMMISSIONING 7

SYSTEM ARCHITECTURE


4.5 Engauge Service Tool The Engauge service tool is a computer application in which all the FlexConn module settings can be performed.

Using the Engauge’s explorer, double-click on the module’s icon to individually select each FlexConn module of the 954 SmartServo FlexLine. The “board descriptor” is loaded which results in a screen with “tab” pages. Select these tab pages, to set the specific module details.

See Figure 4-6 for an example of an Engauge tool.

Figure 4-6 Example of an Engauge screen

SYSTEM ARCHITECTURE


Status Entities in Engauge Each board descriptor user interface starts with the tab page “Status”. In this tab page the “Health” and “Commissioning” entities for the complete module and the individual functions are placed.

Generic Entities in Engauge The “Status” tab page is always followed by the “Generic” tab page, in which the general commands and diagnostics entities are placed.

Board-specific Entities in Engauge The “Generic” tab page is always followed by the “Board specific” tab page, in which the board-specific entities are placed. These entities are specific for each individual FlexConn module type. The board-specific entities are further described in section COMMISSIONING 7

.

Specific Entities on Engauge After the board-specific tab page, for each implemented function on the concerned FlexConn module a specific tab page follows.

For example, for the FII-DO module, the below listed specific tab pages are present:

Relay 1

Relay 2

Relay 3

Relay 4

In case of complex functions, extra tab pages can exist, containing the specific functions involved.

The specific entities are described in section COMMISSIONING 7

Function-generic Entities on Engauge The function category “generic entities” are placed at the bottom of each function tab page in Engauge.

For each category (sensor, digital I/O, communication, display), the basic Engauge version contains only one entity:

“Function identification”.

With this entity, you can change the function name, which is available on the HART SmartView Primary Value screen and in Engauge.

SERVICE TOOLS


5 SERVICE TOOLS

5.1 HART SmartView

General

The HART SmartView is the basic tool in which you can communicate with the SmartServo FlexLine modules.

Open keyboard contacts may be dangerous in an explosion-hazardous environment. The HART SmartView is built up as a totally shielded explosion-safe tool.

HART SmartView Versions

The HART SmartView can be delivered in two versions:

HART SmartView as a tank-side indicator (stand-alone)

A portable HART SmartView

as a tank-side indicator as a portable tool

Figure 5-1 The 2 different HART SmartView options

Connections

Within a hazardous environment, connecting or disconnecting electrical equipment is dangerous, because of the sparking risks.

The portable HART SmartView however is designed such that it may be connected/disconnected within a hazardous zone.

The fixed version HART SmartView (tank-side mounted) contains pre-installed fixed connections.

SERVICE TOOLS


HART SmartView Controls

The HART SmartView has 5 push buttons and an LCD-screen. By using the menu, the 954 SmartServo FlexLine control operations can be performed.

Figure 5-2 The HART SmartView controls

The following table provides the functions of the buttons available on the HART SmartView:

Button Function within menu ...

PV Go to next PV screen

Commissioning Move cursor 1 position to the right

Display contrast Increase contrast

Display settings Toggle between ON and OFF

HART address Toggle between address 7 and 8

PV Go to previous PV screen

Commissioning Leave current menu screen and go to higher-level menu. Important: Leaving an edit screen this way will undo all

Commands Leave current menu screen and go to higher-level menu

Display contrast Decrease contrast

Display settings Toggle between ON and OFF

HART address Toggle between address 7 and 8

+ Commissioning Confirm selected choice

Commands Confirm selected choice

SERVICE TOOLS


Button Function within menu ...

Commissioning Within the menu screens, move cursor 1 line up Within the edit screens, scroll characters as long as the button is pressed

Commands Move cursor 1 line up

Identification Go to next identification screen

Commissioning Within the menu screens, move cursor 1 line down Within the edit screens, scroll down 1 character

Commands Move cursor 1 line down

Identification Go to next identification screen

+ Show menu

Go to PV screen

SERVICE TOOLS


HART SmartView Menu Structure

5.1.5.1 HART SmartView Screens

Depending on the state of the menu process and the pressed button(s), the following screens can be displayed.

SERVICE TOOLS


<<

5.1.5.1.1 Start-up Screen

The HART SmartView starts up displaying the following:

Black test (all pixels ON)

Blank test (all pixels OFF)

Honeywell logo + Software version and checksum

PV screen or the standby screen

5.1.5.1.2 Menu Screen

By using the [menu] screen of the HART SmartView ( Figure 5-3) you can view and/or modify settings, or you can send a specific command to a sensor or a digital I/O board.

MAIN < Figure 5-3 The menu screen

SERVICE TOOLS


Menu Item Description [menu] Screen title. [commissioning] Configuration [commands] Allows you to send a [extra information] The [extra information] [display contrast] Allows you to adjust [identification] Displays information [display settings] Allows you to switch ON/OFF buttons time-out:

• Main screen: If the button is not pressed within 15 minutes, HART SmartView switches to PV screen

• Standby mode: If the button is not pressed within 15 minutes, HART SmartView switches to standby mode

[HART address] Allows you to switch between address 7 and 8

[display test] Performs blank/black test.

[Communication statistics] Display communication errors and activity

Table 5-1 The menu items

5.1.5.1.3 Display Contrast Screen

The [display contrast] screen (see Figure 5-4) displays a horizontal scroll bar. By moving the scroll bar, you can adjust the contrast. Moving to the right immediately increases the contrast, moving to the left decreases the contrast.

Figure 5-4 The display contrast screen

SERVICE TOOLS


5.1.5.1.4 Display Settings Screen

The [display settings] screen allows you to set the time-outs for the buttons. The screen displays the following items:

Feature Possible States DefaultAfter keypad timeout go to main screen ON/OFF ON

5.1.5.1.5 Display Test Screen

When the [display test] screen is selected, the HART SmartView performs a black/blank test. HART SmartView begins drawing a rectangle of 64 x 128 pixels, filled with black pixels for a period of 1 second. After that period, the screen is cleared using a rectangle filled with white pixels for a period of 1 second.

5.1.5.1.6 Identification Screen

The [identification] screen (see examples in Figure 5-5) allows you to scroll through the available FlexConn modules, using the up and down buttons, to obtain information regarding the following:

HART SmartView (see left screen) o the tank name

o the tank address

o customer ID

o HART SmartView

+ address

+ software version

+ software checksum

FlexConn modules (see right screen)

o board name

o board id

o instance

o software version

SERVICE TOOLS


Figure 5-5 Identification screen examples

5.1.5.1.7 Extra Information Screen

The [extra information] mode can be configured to display either the [level & temperature] screen or the [extra information] screen. The [extra information] screen displays information about a specific function. The specific functions are described in section 2478, Operation.

The [level & temperature] screen displays information about the measured product level and temperature. In this menu mode, it is not possible to change any settings.

NOTE: In case of an error situation, the level fields are filled with “#” and the temperature fields with “9”.

Figure 5-6 The level & temperature screen (left), extra information screen (right)

SERVICE TOOLS


5.1.5.1.8 Primary Value Screen

The [Primary Value] screen (PV-screen), displayed in Figure 5-7 depicts information about data measured by a sensor, or information about the status of a digital I/O. See table Table 5-2.

Figure 5-7 PV-screen examples (left: level status, right: digital I/O status)

Data Field Max. Size

[characters] Description

Primary Value 9 The measured value, for example, +025.1277

PV identification 13 Quantity name, for example, • Product level • Product temperature • P1 pressure

PV units 5 Quantity unit, for example • m • kg/m3

• kPa

PV type 3 Type can be: • INN (innage) • ULL (ullage) • REL (relative) • ABS (absolute)

PV health 9 Status of the Primary Value: • UNCERTAIN • BAD

SERVICE TOOLS


Data Field Max. Size

[characters] Description

PV representation 15 Representation of the PV: • Manual • Last valid • Stored • Instrument • Environment • Hardware • Software • Commission • Calibration • Operational • No data • No init. • Killed • Over range • Under range

PV alarms 9 Alarm type that occurred: • High High • High • Low • Low Low

Tank identification 8 Tank name, for example, CRUDE 07

Alive indicator 1 Blinking cursor (bottom right) indicates PV being updated

Table 5-2 Primary Value (PV) items

REMARKS:

1. In error situation, the data fields are filled with “#”.

2. HART SmartView enters standby mode when the communication with the host is lost.

3. The data fields PV health, PV representation, and PV alarms are only visible if they are applicable.

SERVICE TOOLS


5.1.5.1.9 The Password Screen

The [commands] and [commissioning] menus are password-protected. The [password] screen (see Figure 5-8) appears when you enter the [commands] or the [commissioning] menu.

When the password is entered correctly (only once for both menu entries), you can change the values. 15 minutes after the last button is pressed, the password needs to be re-entered.

Figure 5-8 The password screen

5.1.5.1.10 Commands Menu Screens

The [commands] menu starts with the [board list] screen (see Figure 5-9).

You can navigate through the board list by using the up and down buttons. A board can be selected by simultaneously pressing the left + right button

Figure 5-9 The board list screen

SERVICE TOOLS


The [function list] screen (see Figure 5-10) displays all the available functions of the previously selected board. You can navigate through the function list by using the up and down buttons. You can return to the [board list] screen by pressing the left button. A function can be selected by simultaneously pressing the left + right button. If a FlexConn module does not contain any function commands, this is indicated in the list (<no cmd>).

Figure 5-10 The function list screen

When an available function is selected, the [command list] screen is presented (see Figure 5-11). You can navigate through the function list by using the up or down button. A command can be selected by simultaneously pressing the left + right button. You can return to the [function list] screen by pressing the left button

Figure 5-11 The command list screen

SERVICE TOOLS


5.1.5.1.11 Commissioning Menu Screen

The [commissioning] menu starts with the [board list] screen (see Figure 5-12).

You can navigate through the board list by using the up or down button. A board can be selected by simultaneously pressing the left + right button.

Figure 5-12 The function list screen

SERVICE TOOLS


The [function list] screen (see Figure 5-13) displays all configurable entities of a function.

The actual entity value is also visible.

You can navigate through the board list by using the up or down button. A function can be selected by simultaneously pressing the left + right button. You can return to the [board list] screen by pressing the left button.

Figure 5-13 The function list screen (commissioning)

On selection of an available function, the [entity list] screen is presented (see Figure 5-14). You can navigate through the entity list by using the up or down button. An entity can be selected by simultaneously pressing the left + right button. You can return to the [function list] screen by pressing the left button.

Figure 5-14 The entity list screen

SERVICE TOOLS


On selection of an available entity, the [value edit] screen is presented (see Figure 5-15).

o If an invalid value is entered, the message “value out of range” is displayed.

o If the value is not accepted by the FlexConn module, the message “value not accepted” is displayed.

o You can scroll along the characters by push and hold the up button.

o An entity modification is only executed on simultaneously pressing the left + right button. After this, first a range check is performed. If the modification is accepted, you return to the [value edit] screen.

o The cursor can be shifted to the right by pressing the right button.

o You can return to the [entity list] screen by pressing the left button.

NOTE: Use the left button to return to the [entity list] screen without executing the modification(s). Press the left + right button simultaneously to undo this (these) modification(s)!

Figure 5-15 The entity list screen

SERVICE TOOLS


<< < <

5.1.5.1.12 HART address screen

The HART address screen allows you to change the address of the HART SmartView. When the button left or right is pressed the new address is immediately active. The address is stored in non-volatile memory (see Figure 5-16).

MAIN < > MENU SELECT

Figure 5-16 HART address

5.1.5.1.13 Communication statistics

The Communication statistics gives you an overview of the communication stability. (see Figure 5-17)

MAIN < > MENU SELECT

Figure 5-17 Communication statistics

SERVICE TOOLS


Character level errors:

Symbol Description Meaning OR Number of overrun errors The HSV drops characters

FR Number of framing errors The HSV has problems reading the characters

PAR Number of parity errors The characters are corrupt

Message level errors:

Symbol Description Checksum errors Number of received corrupt messages

Unknown msg's Number of unknown messages that the HSV received

Communication Activity:

Symbol Description Tx Number of bytes transmitted after startup in Kb [1024 bytes]

Rx Number of bytes received after startup in Kb [1024 bytes]

SERVICE TOOLS


5.2 Engauge

Connecting the Engauge Service Tool The Engauge service tool is a computer application in which all FlexConn module settings can be performed.

5.2.1.1 Wired Connections Situation

Connecting the serial COM-port of a computer or a laptop through an RS-232 (or RS-485) transmission line to either a Communication Interface Unit (CIU) or a SmartLink, enables the control of a 954 SmartServo FlexLine system. (Figure 5-18)

Figure 5-18 Connecting the Engauge service tool - wired connections

SERVICE TOOLS


Using Engauge After starting the Engauge application, first the specific transmission address of the concerned 954 SmartServo FlexLine system must be set correctly. Also, the transmission speed (baudrate) must be set.

After this is performed, Engauge’s explorer appears, and each FlexConn module of the concerned SmartServoFlexLine system is visible on the left panel. See Figure 5-19.

Double-click on the module’s icon on the left panel to edit each individual 954 SmartServo FlexLine module. The “board descriptor” is loaded and a screen with “tab” pages appears

Figure 5-19 Example (1) of an Engauge screen

Browse through the tab pages to reveal the same information/ parameter settings which can be found using the HART SmartView, but in a more user-friendly way. However, some settings or commands can only be executed by Engauge. For example, executing an Alarm simulation test is only available through Engauge.

INSTALLATION


6 INSTALLATION

Before starting with commissioning activities, first make sure all mechanical and electrical installation aspects have been completed correctly.

For installation see the Installation Manual for the 954 SmartServo FlexLine.

NOTE: Contact our service department for any guidance if needed, through e-mail: [email protected]

Figure 6-1 954 SmartServo FlexLine

COMMISSIONING


7 COMMISSIONING

7.1 Checks before starting the commissioning

Examine the mechanical and electrical installation after the 954 SmartServo FlexLine is installed on the tank. Refer to the installation guide 954 SmartServo FlexLine. See References

Check the correct orientation of the gauge with respect to the tank.

Check that the gauge is levelled within 2°.

Check that the O-ring and gaskets are supplied.

Check that the mains voltage selector of the 954 SmartServo FlexLine indicates the local mains supply.

Check the connections of all electrical cabling.

Check the ground connection of the 954 SmartServo FlexLine to the tank.

Check that non-used cable inlets are sealed with appropriate stopping plugs.

Close carefully all covers (mind the O-rings) before any electrical power is applied.

Caution

Keep screw thread from the compartment covers free from dirt. Grease them lightly with an acid-free grease before closing the instrument. When closing, turn the covers counter-clockwise until the thread clicks into place, then turn clockwise.

COMMISSIONING


7.2 Installation of measuring drum and displacer

Tools It is recommended to use a HART SmartViewto load the different parameters. A tool set for commissioning and maintenance is available from Honeywell Enraf (see

Figure 7-1)

Figure 7-1.

COMMISSIONING


Item Description

1 Allen key 2 mm

2 Allen key 3 mm

3 Allen key 4 mm

4 Allen key 5 mm

5 Allen key 8 mm

6 Drum bearing puller

7 Test magnet

8 Screwdriver for Allen key screws M4

9 Screwdriver for Allen key screws M6

10 Pipe wrench 27 mm

11 Tommy bar

Figure 7-1 Tool set for 954 SmartServo FlexLine (part no. A1854062)

COMMISSIONING


Installation of measuring drum

Remove the drum compartment cover (rear cover). Check whether the drum shaft is properly positioned in the

drum. Remove the drum compartment cover (rear cover). Check whether the drum shaft is properly positioned in the

drum. Attach the smallest of the four test weights (or another small

weight) to the measuring wire, remove the rubber band securing the measuring wire and feed the wire and test weight through the neck of the gauge (see Figure 7-2)Insert the measuring drum onto its bearings.

Check the axial free-play of the drum as follows: Push the drum towards the magnet cap in such a way that the

drum shaft meets the magnet cap. Release the drum. Bring the drum in a slight vibration. The drum and drum shaft

should now move towards you with a axial movement of minimum 1 mm and maximum 2.5 mm.

Note the engraved drum circumference value on a piece of paper for later use. There are several numbers engraved on the measuring drum. The number you are looking for has a value of approximately 338 mm (for example: 338.028).

Figure 7-2 Installing drum

COMMISSIONING


Installation of displacer If a density displacer is used, note the engraved displacer

weight and displacer volume on a piece of paper for later use.

Remove the test weight and attach the displacer to the wire through a mounting hatch.

Note: If there is no mounting hatch available, the displacer can be installed by temporarily removing the gauge from the nozzle.

To provide electrical contact between the measuring wire and displacer, thus permitting the discharge of static electricity and preventing loss of the displacer, the displacer must be secured to the measuring wire.

Take an extra piece of wire and fasten one end to the measuring wire, pass the other end through the hole in the end of the displacer hook. Secure this end several times around the hook Mounting displacer (see Figure 7-3).

Close the drum compartment cover.

Figure 7-3 Mounting displacer

COMMISSIONING


Unlocking (locking) the motor block The motor block is locked during transport to protect the

force transducer. After installing the measuring drum and displacer, the motor block locking device must be unlocked.

Open the electronic compartment cover (front cover).

Locate the transport bracket (see Figure 7-4) Loosen (do not remove) the Allen key screw and turn the transport bracket the opposite way. Use screwdriver for Allen key screws M4 (item 8 of the Honeywell Enraf tool set).

Fix the Allen key screw of the transport bracket. • Check the span wire. It should always be under tension while both ends are correctly positioned in the levers of the motor block and force transducer.

Close the electronic compartment cover.

Figure 7-4 Motor block (un)locked

Note: Use the same procedure for locking the motor block if the 954 SmartServo FlexLine needs to be removed.

COMMISSIONING


7.3 Configuring FlexConn boards

Introduction This chapter provides an overview of the commissioning information as per the FlexConn module.

NOTE: Not all modules are always present.

Commissioning a FlexConn module is performed by setting software parameters and the entities (see 0

COMMISSIONING


Entities), to the desired specific values. This can either be performed by using Engauge or HART SmartView (see 5.1 HART SmartView).

Text Conventions

In contrast with explanatory text, all instruction text is preceded by a ☛

All [Entity] and <entity-related> text is recognizable formatted. When - for instance - all required FlexConn module entities are commissioned, the [Board Commissioned] entity displays <True>. If not, it displays <False>.

All !Command! text is also recognizable formatted, If - for instance - an !Activate! command is given, the result is <Activated>.

In this chapter, each commissioning-instruction text is recognizable by the Engauge/HART SmartView icon in the margin.

When a commissioning instruction or command cannot be initiated by HART SmartView, the icon is provided.

COMMISSIONING


Enraf Fieldbus (HCI-BPM)

7.3.3.1 Introduction

The Host Communication Instrument - Bi-Phase Mark (HCI-BPM) board is a communication module for the instrument (gauge).

Figure 7-5 The HCI-BPM board with its isolation transformer

As a result of any requirements on the cable quality, the connection of 10 to 15 devices per field bus, and cable lengths up to 10 km, the Bi-Phase Mark (BPM) signalling is used in many data transmission installations between various instrumentation and Communication Interface Unit (CIU) configurations.

Also, the BPM technology provides excellent protection against lightning. For the exchange of the BPM signals, the HCI-BPM board uses an isolation transformer for galvanic isolation (see Figure 7-5). Further protection against heavy lightning is realized by internal ground shields, separated wiring, and ground tracks.

COMMISSIONING


The HCI-BPM module supports the following two protocols

• The Enraf GPU protocol with its records and items (limited);

• The Enraf FlexConn protocol with its entities.

The module can communicate with the following:

• 880 CIU prime

• 858 CIU

• 780 SmartLink

7.3.3.2 Commissioning the HCI-BPM

For a correct functioning of the HCI-BPM module in an instrument (gauge), the following entities can be set by using either Engauge or HART SmartView.

☛ By using the following table, check each entity for correctness.

Name Value Range Default Value Explanation [Baudrate] <1200>

<2400> <4800>

<1200> Communication speed

[BPM sensitivity] <1..8> <8> The sensitivity of the receiver circuit. 1 = weakest 8 = strongest

[Identification] 8 characters for example,<TANK1234>

<--------> Name of a tank or instrument.

[GPU instrument address] <0..99> <0> The address of this instrument for GPU messages. Note: Each instrument must have a unique GPU address.

[FlexConn instrument address] <0..1899> <0> The address of this instrument for FlexConn messages. Note: Each instrument must have a unique FlexConn address.

[Level units] <Meters> <Inches> <Feet> <Fractions>

<Meters> The unit in which level- related GPU records and items are displayed.

[Temperature units] <Celsius> <Fahrenheit>

<Celsius> The unit in which temperature-related GPU records and items are displayed.

COMMISSIONING


Name Value Range Default Value Explanation [Pressure units] <pascal>

<kilo pascal> <psi small> (2 digits before separator) <psi large> (3 digits before separator)

<pascal> The unit in which pressure- related GPU records and items are displayed.

[Density units] <kilogram m3> <degrees API> <pounds ft3>

<kilogram m3> The unit in which density- related GPU records and items are displayed.

[Decimal separator] <point> <comma>

<point> The decimal separator in which GPU-related records and items are displayed.

[Level type] <innage> <ullage>

<innage> The level-related GPU records and items can be shown as an innage or ullage. Note: • Innage is the level of the

product measured from the bottom.

• Ullage is the level of free space from the roof till the product.

[Password] <......> 6 characters <ENRAF2> Password for entering the protected level. Note: Some settings reside under the protected level.

[Function identification] <......> 13 characters <BPM-slave> The name of the current function of this module. This name is visible on the HART SmartView display.

☛ After having checked/set all before listed entities, make sure you check the following:

The [Board Commissioned] and the [BPM slave Commissioned] entities are <True>.

The [Board Health] and the [BPM slave Health] entities are <GOOD>.

COMMISSIONING


Product Level Measurement (TII-SRV) 7.3.4.1 Introduction

The CAN-SERVO FlexConn board of the 954 SmartServo FlexLine runs the application firmware named TII-SRV.

Figure 7-6 CAN-SERVO FlexConn board

COMMISSIONING


The CAN-SERVO board contains the following high level functions:

Element Description

Vibration sensor Sensor on the CAN-SERVO board measuring vibrations (acceleration).

Stepper motor Motor to control the drum position in order to be able to raise or lower the displacer position in the storage tank.

Encoder Transmits unique patterns in order to read out the motor position by the firmware.

Force transducer Measuring the force the displacer is applying to the servo system represented as a frequency.

Magnet temperature sensor

An interface on the CAN-SERVO board to a temperature sensor positioned inside the gauge in such a way that it represents the temperature of the magnet in order to be able to compensate for

COMMISSIONING


Element Description

temperature dependency of the magnetic field. By this magnet temperature measurement, the firmware compensates the level calculation.

W&M jumper Weight and Measures jumper or switch located on every FlexConn board for protecting modification of W&M relevant entities (device parameters) and firmware. The W&M status is daisy chained to the other boards so only one of the boards need to be set to protect / seal status and all other boards will read that protect / seal status.

External watchdog In addition to an internal watchdog in the micro controller the CAN-SERVO board implements an external watchdog in order to improve the SIL hardware FMEDA figures.

RTC Real Time Clock used for date and time stamping of measurements and diagnostics.

Low power Signal generated by the CAN-SERVO board in case the power drops below a certain threshold where the firmware needs stop the servo stepper motor and store relevant operational data in non-volatile memory e.g. motor position.

NV memory Non-volatile memory to store diagnostic data, operational data (e.g. motor position) and configuration parameters (entities).

The TII-SRV firmware supports the following process data measurements reflected in a Primary Variable (FlexConn PV):

• Displacer level (innage, ullage is in Secondary Variable)

• Product level (innage, ullage is in Secondary Variable)

• Interface level (innage, ullage is in Secondary Variable)

• Water level (innage, ullage is in Secondary Variable)

• Average density

The TII-SRV firmware supports the following operational modes:

• Interface 1 (vapor – product interface)

• Interface 2 (product – product interface)

• Interface 3 (product – water interface)

• Dip mode (vapor – product interface, avoiding contamination or damaging of the displacer)

COMMISSIONING


The TII-SRV firmware supports the following process data commands:

• Water interface dip

• Density tank profile dip

• Density interface profile dip

• Density-Water dip

• Water-density dip

The TII-SRV firmware supports the following displacer action and diagnostic commands:

• Block

• Freeze

• Find encoder position (calibrate)

• Accept reference

• Unlock

• Test gauge

• Lock test

• Calibrate

• Test

• Lock test to level

• Lock to level

• Go down

• Go up

• Balance test

• Set maintenance mode

• Set operational mode

• Check bearings

• Run down test (free run analyses)

• Servo Auto Test (SAT, check for blockage)

• Alarm test commands

• Frequency calibration (measure frequency)

COMMISSIONING


The TII-SRV firmware supports the following configurable compensations:

• Wire weight compensation

• Mechanical hysteresis elimination

• Magnet temperature compensation

• Tank shell temperature compensation for high tanks

• Compensation for wire expansion over temperature

• Wire elongation compensation for free wire

• Wire elongation compensation for wire on drum

• Density compensation for level measurement

• Hydrostatic deformation compensation

• Unbalance compensation

• Roof Immersion Compensation

• Drum temperature compensation

• Displacer volume compensation for pressure for density measurement

• Displacer volume compensation for temperature for density measurement

• Tilt compensation for density measurement

For correct functioning of the TII-SRV module in the instrument, the following entities can be set by using either Engauge or some by SmartView, summed up per Engauge tab.

COMMISSIONING


7.3.4.2 Board specific

Name Value Range Default Value Explanation

[Date and time] Shows the date and time of the RTC chip.

[Write date and time] <2018,1,1,0,0,0> Here you write the actual date and time you want to set.

[Set date and time] This command sets the new entered date and time to the RTC.

[Run hours] Shows the amount of hours the servo continuously has run.

[Magnet temperature]

Shows the magnet temperature with a status whether it is valid or not.

[Voltage CPU core] Shows the measured voltage of the CPU core.

[Board W&M intended]

<enable>

<disable>

<disable> This board can be W&M sealed. Therefor the user needs to set this board as W&M intended.

[W&M unseal step 1] This command can be given if the user wants to remove the (electronic) W&M seal.

It is done in 2 steps. This is step 1.

Next entity is step 2.

[W&M unseal step 2] This command is step 2 of the remove W&M seal procedure. After this command the seal is removed.

COMMISSIONING


Name Value Range Default Value

Explanation

[Sales code] < 32 char’s > < 32 ‘-‘ > In production / commissioning the sales code can be set and can here also be read.

[Device serial number] In production the device serial number can be set and can here be read.

[Production date] In production the production date can be set and can here be read.

[Drum serial number] In production / commissioning the drum serial number can be set and can here also be read.

[Device tamper counter

<0.0> Shows how many times a ‘user’ tried to change a setting when the ‘protect all entities jumper’ is active.

[Device tamper date and time]

<all 0> Shows the last 10 time stamps when the device tamper was detected.

[W&M tamper counter] <0.0> Shows how many times a ‘user’ tried to change a setting when the ‘Protect W&M entities jumper’ is active.

[W&M tamper date and time]

<all 0> Shows the last 10 time stamps when the W&M tamper was detected.

[Actual acceleration] <all 0> Shows the actual x-, y-, z-axis acceleration values of this sensor.

[Maximum acceleration]

<all 0> Shows the maximum x-, y-, z-axis acceleration values of this sensor.

[Minimum acceleration]

<all 0> Shows the minimum x-, y-, z-axis acceleration values of this sensor.

[Proto board] <true>

<false>

<false> Determines whether this servo board is a prototype board. Important for hardware version detection.

COMMISSIONING


7.3.4.3 Product level


[Primary value] Shows the measured product level (I1 interface) as an innage value, with the following fields:

<value> The level

<status>

Good = All ok.

Bad = Level fail.

Uncertain = Level in reduced accuracy.

<status category> the category related to the status, e.g:

-Status category good actual

-Status category bad no data available

<status code> more detailed information about the status, e.g:

-Interface 1 command active

-Temperature monitor high limit exceeded

<alarm status> Indicates no-, high-, high high-, low- or low low- alarm of this primary value

<qualification> Extra information such as

Bit0: W&M approved

Bit1: Motor limit high or low reached

Bit2: & Bit3: 00 = stable level 01 = displacer going up 10 = displacer going down 11= SAT active

Bit4: On level light flag is true (‘Old’ Test flag is false)

Bit5:..Bit7: Not used

COMMISSIONING



[Primary value gain] <1.0> The calculated primary value can be multiplied with a desired gain.

[Primary value offset] <0.0> The calculated primary value can be given an offset.

[Secondary value]

Shows the measured product level as an ullage value with the same fields as explained at the primary value.

[High high alarm]

[High alarm]

[Low alarm]

[Low low alarm]

[Alarm hysteresis]

All <1E+22> Sets the respectively alarm threshold for the primary value, taking in account the hysteresis.

[Alarm test enable] <Enable>

<Disable>

<Disable> When enabled, during one minute there will be a simulated alarm, determined by entity [Alarm test], by putting the primary at the [Alarm test] threshold plus or minus 1/8 inch.

[Alarm test] <No alarm>

<High alarm>

<High high alarm>

<Low alarm>

<Low low alarm>

<No alarm> Determines which alarm test threshold will be simulated

[Kill measurement] With this command the actual measured primary value can be undone (killed). The purpose is then to overwrite this measured value.

[Manual overwrite] The desired overwritten primary value (If killed).

[Resurrect] With this command the manual overwritten value will be undone, and the Primary value shows it normal measured value.

[Manual overwrite status] Shows the actual manual overwrite status. (Active or inactive)

[Operational status] Shows the actual operational status. (I1, I2, I3 or DM)

COMMISSIONING


7.3.4.4 Displacer level


[Primary value] Shows the actual displacer position as an innage value.

Fields, see product level

[Primary value gain] See product level

[Primary value offset] See product level

[Secondary value]

Shows the actual displacer position as an ullage value.


[High high alarm]

[High alarm]

[Low alarm]

[Low low alarm]

[Alarm hysteresis]

See product level

[Alarm test enable] See product level

[Alarm test] See product level

[Kill measurement] See product level

[Manual overwrite] See product level

[Resurrect] See product level

[Manual overwrite status] See product level

[Operational status] Shows the actual operational status. (I1, I2, I3 or DM)

COMMISSIONING


7.3.4.5 Water level


[Primary value] Shows the (dipped/searched) water level (I3 interface) as an innage value.




[Secondary value]

Shows the (dipped/searched) water level (I3 interface) as an ullage value.


[High high alarm]

[High alarm]

[Low alarm]

[Low low alarm]

[Alarm hysteresis]

See product level







COMMISSIONING


7.3.4.6 Functional safety level


[Functional safety level] Shows the functional safety level as a copy of the current product level. This level can be scanned from the CAN-SIL board, which will guard the overfill and underfill protection.

It has the same fields as the product level but in addition to that:

<Time counter> Shows the CPU system counter in ms. (Starts at 0 after reset)

<Source board id> Shows the Flexconn board id of the owner of this functional safety level, in this case 24.

<CRC-16> shows the calculated CRC-16 value over all previous fields.

COMMISSIONING


7.3.4.7 Interface 2 level


[Primary value] Shows the (dipped/searched) interface 2 level as an innage value.




[Secondary value]

Shows the (dipped/searched) interface 2 level as an ullage value.


[High high alarm]

[High alarm]

[Low alarm]

[Low low alarm]

[Alarm hysteresis]

See product level







COMMISSIONING


7.3.4.8 Density


[Primary value] Shows the calculated density value after a density profile or tank profile command.




[Secondary value] N.A.

[High high alarm]

[High alarm]

[Low alarm]

[Low low alarm]

[Alarm hysteresis]

See product level







[Density data] During a density measurement, a maximum of 50 density/level points will be presented with the following fields:

<index> the density/level point number.

<density status byte>

<density value>

<level status byte 1>

<level status byte 2>

<level value>

(status bytes according to items [D0] and [R0])

COMMISSIONING


7.3.4.9 Operational commands


[Host command mode] <Enable>

<Disable>

All <Enable> With this entity the user can enable or disable the following commands:

-Interface 1

-Interface 2

-Interface 3

-Block

-Calibrate

-Dip mode

-Freeze

-Interface profile

-Lock test

-Test gauge

-Tank profile

-Unlock

-Density water dip

-Water density dip

-Test

-Lock to level

-Lock test to level

[Freeze] This command stops the motor. This situation will be maintained until a [Unlock] command is given.

[Test gauge] This command will rise the displacer 6 cm. up and after that the interface is searched again. (reproduction test)

COMMISSIONING



[Block mode] <continuous>

<non continuous>

<continuous>

With this entity the user can select whether the Block command

remains active after the selected interface has reached the displacer.

Set to continuous the Block command will

remain active until another operational command with sufficient priority

interrupts the Block command. The displacer will follow the interface.

Set non continuous the Block command will also

be canceled if the product reaches the displacer.

[Block] This command stops the level measurement,

See also Block mode

[Unlock] This command is used to break off any active operational command.

After an Unlock command the 954 returns to the default operation mode.

[Lock test] This command will raise the displacer up till it reaches [Motor limit switch high] or [Lock test limit level].

If motor limit high reached, the displacer remains there (until e.g. Unlock has been given)

If lock test limit reached, the command mode will be changed to Block.

[Lock test limit level] <50.0> Level at which the Lock test command will stop the displacer and the command mode will change to Block.

[Calibrate] This command will raise the displacer up until it reaches the calibration plate. This position (innage level) will be compared with [Tank top]. If the difference is too big a fail is issued.

COMMISSIONING



[Lock test stop level] <0.0> Determines the level to which the displacer goes after a Lock to level, Lock test to level or Test command.

[Lock to level] This command sends the displacer to the [Lock test stop level] and remains there.

[Lock test to level] This command sends the displacer to the [Lock test stop level] and when reached, issues an Unlock command and the displacer returns to the selected interface.

[Test] This command sends the displacer to the [Lock test stop level] and when reached, issues a Block command and after some time issues an Unlock command and the displacer returns to the selected interface.

[Water interface dip] This command searches for the water level and after that returns to the default operation mode.

[CIU water interface dip]

This command searches for the water level and stays there.

COMMISSIONING


7.3.4.10 Special commands


[Interface 1] This command activates the Servo to search for interface 1, the so called vapor-product interface, typically called the product level. It uses [Setpoint 1] and [Integration time 1] settings.

[Interface 2] This command activates the Servo to search for interface 2, the so called product with density A-product with density B interface, typically called the interface 2 level. It uses [Setpoint 2] and [Integration time 2] settings.

[Interface 3] This command activates the Servo to search for interface 3, the so called product-water interface, typically called the water level. It uses [Setpoint 3] and [Integration time 3] settings.

[Dip mode] This command will set the displacer at some distance [Dip Height] above the interface 1. After some time [Dip time] the interface 1 is searched/dipped and the displacer will return back to the dip height position.

COMMISSIONING


7.3.4.11 Configuration


[Displacer type] <no_displacer_type_selected> <s0815345_cptfe_110mm> <s0815344_cptfe_90mm> <s0815343_cptfe_45mm> <s0815360_cptfe_25mm> <s0815350_aisi316_density_90mm><s0815355_aisi316_density_45mm><s0815316_stabigauge_90mm> <s0815362_cptfe_spider_90mm> <other_displacer_type>

<No displacer type selected>

During commissioning a displacer type can be selected from a list.

[Measuring range and wire material]

<no_measuring_range_selected> <27m_88ft_aisi316> <27m_88ft_hastelloy_c22> <27m_88ft_tantalum> <37m_121ft_aisi316> <37m_121ft_invar> <37m_121ft_tungsten> <47m_154ft_aisi316> <47m_154ft_tungsten> <150m_492ft_aisi316> <other_measuring_range_or _wire_material>

<No measuring range selected>

During commissioning the measuring range and wire material can be selected from a list.

[Drum circumference]

<0.0> The drum circumference.

[Set point 1] <0.208> This entity defines the wire weight/tension if it reaches the interface 1 (product level) transition.

[Set point 2] <0.208> This entity defines the wire weight/tension if it reaches the interface 2 (2 different product densities) transition.

[Set point 3] <0.208> This entity defines the wire weight/tension if it reaches the interface 3 (water level) transition.

COMMISSIONING



[Upper reference level] <27.0> The upper reference level is used to compute the ullage level.

The ullage level is defined as:

Ullage level = Upper reference level - innage level..

[Tank top level] <100.0> The Tank top level is used during a calibration test to determine if the calculated innage is still within acceptable range.

[Motor limit switch high] <100.0> The motor limit switch high level indicates the highest position the displacer

may reach during normal operation.

This limit needs to be more than 10 mm above the low limit.

[Motor limit switch low] <200.0> The motor limit switch low level indicates the lowest position the displacer

may reach during normal operation.

[Dip Height] <0.3> Determines how high the displacer will stay above the Interface 1 (Product level) during dip mode.

[Dip interval time] <60> Determines the time in between 2 consecutive interface 1 dips

[Reference level] <-100.0> Level used to set the innage product level.

[Accept reference] This command sets the innage product level indicated by the reference level.

COMMISSIONING


7.3.4.12 Advanced Configuration


[Displacer area] <0.0065> The displacer area must be entered at the point where the displacer touches the interface when the control loop is in balance.

[Integration time 1] [Integration time 2] [Integration time 3]

<2> <2> <2>

Used to filter out (fast) fluctuations of the resp. interfaces 1, 2 and 3.

[Wire weight per unit of length]

<0.00025> This entity is used to compensate the set point with the weight of the wire.

[Wire temperature coefficient]

<1.2E-05> Determines the temperature expansion coefficient of the wire (according to a related table)

[Wire cross sectional area]

<3.1416E-08> Determines the cross sectional area of the wire.

[Elasticity coefficient]

<2E+11> Determines the elasticity coefficient of the wire (according to a related table)

Drum blind length <0.0> Determines the non used part of the wire on the drum when the wire length > 50m till 150m. concerning related calculations.

COMMISSIONING


7.3.4.13 Density configuration


[Displacer volume] <110> The displacer volume.

[Displacer weight] <223> The displacer weight in air.

[Density scan direction] <Scan direction up>

<Scan direction down>

<Scan direction down>

Determines whether the density measurements are performed downwards (from e.g. product level) or upwards (from e.g. the bottom). See also start and stop level entities.

[Number of density measurement points]

<1..50> <10> Determines over how many points (levels) the interface or tank profile density measurements are done.

[Density interface profile start level]

<-999.9999> Determines the interface profile start level from where the density measurements are performed.

[Density interface profile stop level]

<-999.9999> Determines the interface profile stop level until where the density measurements are performed.

[Interface profile] This command starts a interface profile density measurement. The density measurement positions are equally distributed from the range:

[Density IP start level] until [Density IP stop level] with the number of points defined by [Number of density measurements (max 50)].

[Number of tank profile drum balance points]

<1..32> <10> Determines the number of points over the drum circumference at a level position used for the tank profile density measurement.

[Density tank profile start distance]

<0.3> Determines the tank profile start level from where the density measurements are performed. This means the product level minus this start distance.

COMMISSIONING



[Default density tank profile stop level]

<0.3> Determines the tank profile stop level until where the density measurements are performed. The highest is used, see next entity.

[Density tank profile stop level]

<-999.9999> Determines the tank profile stop level until where the density measurements are performed. The highest is used, see previous entity.

[Density tank profile method]

<One drum position>

<Multi over drum>

<Multi over drum> Determines (at a certain level position) if the density measurements are done at only one point at the drum circumference (unbalance compensation could help here) or at multiple points over the drum circumference (would filter out drum unbalance at the same time). The number of points is determined by the entity [Number of tank profile drum balance points]

[Air density] <1.225> This air density is used during density calculations.

Liquid surface pressure]

<101.3> The pressure at the liquid surface inside the tank.

Note: For pressurized tanks this should be the value for the pressure inside the tank.

[Tank profile] This command starts a tank profile density measurement. The density measurement positions are equally distributed from the range: Product level – [Density TP start distance] until [Density TP stop level] or [Default density TP stop level] with the number of points defined by [Number of density measurements (max 50)].

COMMISSIONING



[Water density dip] This command first searches for the water level and after that performs a density measurement upwards. And then returns to the default operation mode.

[Density water dip] This command first performs a density measurement downwards and after that searches for the water level. And then returns to the default operation mode.

[Density compensations]

<enable> <disable>

<enable> <enable> <disable> <enable>

Enable or disable the following compensations for the density: -Tilt Calibrates the density measurement for tilt of the gauge -Unbalance Compensates density for the unbalance of the drum -Unused -Volume Compensates density for hydrostatic deformation of the displacer

COMMISSIONING


7.3.4.14 Compensation


[Setpoint compensation] <enable>

<disable>

<enable>

<disable>

<disable>

Enable or disable the following compensations for the set point:

-Wire weight

Compensates for the wire weight

-Unbalance

Compensates for the unbalance of the drum and bearings

-Density

Compensates for the change in density over time

[Compensation wire weight]

Shows the wire weight compensation.

[Compensation unbalance]

Shows the unbalance compensation.

[Compensation density] Shows the density compensation.

[Level compensation] <enable>

<disable>

<enable>

<enable>

<disable>

<disable>

<disable>

<disable>

<disable>

<disable>

Enable or disable the following compensations for the level:

-Magnet coupling

Compensates level for the slip in the magnet coupling caused by different weights

-Magnet coupling temperature

Compensates level for the slip in the magnet coupling caused by temperature

Note: Only applied when Magnet coupling compensation also is enabled.

Note: Both magnet couplings should be (default) enabled

COMMISSIONING



[Level compensation] <enable>

<disable>

<enable>

<enable>

<enable>

<enable>

<disable>

<disable>

<disable>

<disable>

-Wire temperature

Compensates level for the expansion of the

wire caused by temperature

-Elongation free wire

Compensates level for the expansion of the wire between drum and displacer caused by weight

-Elongation wire on drum

Compensates level for the expansion of the wire on the drum caused by weight

-Tank shell

Compensates level for the expansion of the tank shell caused by temperature

-Hydrostatic deformation

Compensates level for the hydrostatic deformation of the tank

-Roof immersion

Compensates level for the weight of snow on the floating roof

[Compensation magnet coupling]

Shows the magnet coupling compensation, which is the sum of the 2 magnet coupling compensations

[Compensation wire temperature]

Shows the wire temperature compensation

[Compensation free wire elongation]

Shows the free wire elongation compensation

[Compensation wire on drum elongation]

Shows the wire on drum compensation

COMMISSIONING



[Tank shell expansion coefficient]

<1.6E-05> Determines the expansion coefficient of the tank shell material

[Tank shell reference temperature]

<20> Determines the reference temperature for the tank shell compensation

[Tank shell ambient temperature selection]

<TII-SRV board>

<Broadcasted>

<FII-RTD board>

<Magnet sensor>

<TII-SRV board>

Determines the source for the ambient temperature

[Tank shell vapor ambient ratio]

<0.5> Determines the ratio of vapour and ambient temperatures for calculation of the dry part of the tank shell temperature

[Tank shell product ambient ratio]

<0.875> Determines the ratio of product and ambient temperatures for calculation of the wet part of the tank shell temperature

[Tank shell temperature dry part]

Shows the calculated temperature of the dry part of the tank shell

[Tank shell temperature wet part]

Shows the calculated temperature of the wet part of the tank shell

[Compensation tank shell] Shows the tank shell compensation

[Compensation tank top] Shows the tank top compensation due to the tank shell compensation

[Hydrostatic deformation level]

<2> Contains the innage above which the compensation becomes effective. Below this innage no compensation is applied

[Hydrostatic deformation factor]

<0> Contains the compensation factor

COMMISSIONING



[Compensation hydrostatic deformation]

Shows the hydrostatic deformation compensation

[Compensation roof immersion]

Shows the roof immersion compensation

[Compensation level drum temperature]

Shows the level compensation due to drum temperature.

[Scanned product temperature]

Shows the fetched product temperature from another board

[Scanned vapour temperature]

Shows the fetched vapour temperature from another board

[Scanned lowest spot temperature]

Shows the fetched lowest spot temperature from another board

[Scanned RTD ambient temperature]

Shows the fetched RTD ambient temperature from another board

[Broadcasted ambient temperature

Shows the broadcasted ambient temperature from the CIU

[Tank shell used ambient temperature]

Shows the used ambient temperature for the tank shell compensations

COMMISSIONING


7.3.4.15 Maintenance

Name Value Range Default Value Explanation [Wire tension protection]

<enable> <disable>

<enable> With this entity the possibility exists to enable or disable the wire tension high and low check. If enabled a high or low fail code will be generated if the tension exceeds the low or high thresholds.

[Drum slip detection]

<enable> With this entity the possibility exists to enable or disable the drum slip detection. If enabled a drum slip fail code will be generated if the measured frequency is below a certain limit.

[Drum slip occurrence]

Shows the number of drum slip occurrences

[Motor position errors]

Shows the number of observed slip detections of the reference encoder

[Set to Maintenance mode]

This command resets the Servo board and after that enters the maintenance mode. In this mode there are no level measurements. Now the 4 frequencies can be measured or the find reference encoder can be done. A limited number of commands can be issued.

[Operational mode] Shows the mode the gauge is in: Operational or Maintenance

[Find reference encoder position]

This command determines the reference encoder position and synchronizes this with position. Only available in Maintenance mode.

[Frequency 0] [Frequency 1] [Frequency 2] [Frequency 3]

<0.0> <0.0> <0.0> <0.0>

Frequency measured at resp. 25, 100, 175 and 250 g. load on the wire.

[Measure frequency]

This command will measure the frequency with the actual displacer/weight. The result is placed in entity [Measured frequency].

COMMISSIONING


Name Value Range Default Value Explanation [Measured frequency status]

<active, not active>

This entity gives the status whether the F0..F3 are being measured.

[Measure frequency F0]

This command will measure the frequency with the actual attached weight of 25 g. The result is placed in entity [frequency 0].







[Measured frequency]

This entity holds the measured frequency after the [Measure frequency] command has been given.

[Measured weight] This entity holds the measured weight of the displacer after the [Measure frequency] command has been given.

[Measured compensated weight]

This entity holds the measured weight of the displacer minus the wire weight after the [Measure frequency] command has been given.

[Measured frequency continuously]

Shows the continuous measured frequency

[Go up] This command will let the displacer run up continuously. It can only be activated during maintenance mode. The command can be interrupted by Freeze or Go down command. No wire tension check!

COMMISSIONING


Name Value Range Default Value Explanation [Go down] This command will let the

displacer run down continuously. It can only be activated during maintenance mode. The command can be interrupted by Freeze or Go up command. No wire tension check!

[Set to operational mode]

This command leaves the maintenance mode and the Servo board starts up normally.

[Run down] This command will let the displacer go up until the start position has been reached and then the displacer goes down until the stop position has been reached. After that the actual interface will be searched.

[Run down start position]

<27.0> Determines the start position from where the run down test will be performed, see above.

[Run down stop position]

<0.0> Determines the stop position to where the run down test will be ended, see above.

[Balance test number of test points]

<8> The number of test points equally distributed over the drum circumference.

[Balance test result maximum weight]

The maximum weight found during the balance test.

[Balance test result minimum weight]

The minimum weight found during the balance test.

[Balance test result average weight]

The average weight found during the balance test.

[Balance test result average frequency]

The average frequency found during the balance test.

[Balance test reference motor offset]

<0> Determines the shifted drum position after a balance test and can be set here before an Accept reference command.

[Balance test unbalance]

Shows the found unbalance weight during an unbalance test.

[Balance test] This command activates the measuring of the (un)balance of the drum, by measuring the minimum and maximum weight during one revolution of the drum.

COMMISSIONING


Name Value Range Default Value Explanation [Check bearings raise height]

<0.02> Determines the raise height at which the displacer is risen for the bearings test

[Check bearings] This command activates the check bearing test

[Measured bearings status]

Shows the measured frequency, bearings status and timestamp after the command has been given

COMMISSIONING


7.3.4.16 Servo auto test


[SAT upwards] With this command a manual SAT upwards can be performed.

[SAT downwards] With this command a manual SAT downwards can be performed.

[Autonomous SAT enable] <SAT disable>

<SAT enable up>

<SAT enable up and down>

<SAT enable up>

Determines whether the SAT is disabled, or enabled for upward movements, or enabled for upward and downward movements.

[SAT raise height up] <0.02> Determines the upward raise height.

[SAT raise height down] <0.02> Determines the downward raise height.

[SAT interval time] <60> Determines how often the SAT is performed.

[SAT sample interval] <60> Determines the time period for checking if there is a stable level.

[SAT trip distance] <0.003> Determines if the level can be called stable. That means if the previous measurement level compared to the current measurement is still within the trip distance.

[SAT weight limit up] <0.005> Determines the maximum weight change if the displacer is raised.

[SAT weight limit down] <0.005> Determines the maximum weight change if the displacer is immersed.

[SAT immersed weight limit]

<0.18> Determines the maximum total weight if the displacer is immersed.

COMMISSIONING



[SAT frequency limit] <120> Determines the maximum frequency change when the displacer has been raised.

[SAT intended interface] <Interface 1>

<Interface 2>

<Interface 3>

<Interface 1>

Determines at/around which interface the SAT is performed.

[SAT invalidate level] <enable>

<disable>

<disable> Determines if the actual interface will go the health BAD during the SAT.

[SAT level last fail] 999.9999 Shows the level at which the last SAT failed.

[SAT level last executed] Shows the interface level at the moment the SAT was performed.

[SAT minimum level executed]

Shows the minimum interface level where the SAT was performed.

[SAT maximum level executed]

Shows the maximum interface level where the SAT was performed.

[SAT highest number of retries]

Shows the number of retries in case a SAT performance failed.

[SAT number of executed tests]

Shows the number of SAT’s performed since the gauge was powered up.

[SAT status] Shows the result of the last performed SAT.

[SAT time elapsed since last SAT]

Shows the elapsed time since the previous SAT

[SAT RTC last fail] Shows the date of the RTC when there was a SAT fail.

COMMISSIONING


7.3.4.17 Roof Immersion (RIC)


[HART level addr 11,12,13]

Shows the level measured by the HART probe at HART address 11,12,13, takelcd

n into account the configured units.

[Status] Shows the status of the calculated RIC compensation factor, which can be:

No error

RIC configuration parameters not commissioned

Product level below RIC minimum level

Error getting HART dynamic variables entity device address 11



Wrong HART units device address 11



Bad HART status device address 11



[Compensation factor]

Shows the calculated compensation offset due to the roof immersion. This will be applied to the L-record. Normally this will be a negative number.

[Probes scan board id]

<0..255> <0> Determines the board id where the probes are connected. This can be:

6 : FCI-HT

7 : FII-VT

23: FCI-HRT

[Probes scan board instance]

<0..7> <0> Determines the board instance of the above mentioned board.

[Method] <Geometrical>

<Roof weighing>

<Geometrical> Two possible methods for doing the calculations. They are recommended by the Polish Weight and Measures Institute called the G.U.M.

[Total surface area product]

<0.0> Determines the total surface area of the product in the tank.

COMMISSIONING



[Total cross section area roof]

<0.0> Determines the total cross section area of the floating roof (which will be less then total surface area of the product)

[Interstice section area roof]

<0.0> Determines the total interstice section between the floating roof and the tank wall.

[Average height measuring pipe]

<0.0> Determines the arithmetic mean of the heights of three measuring pipes, measured from planes determined by their top edges to the plane determined by the lowest edge of the pontoon bottom.

[Reference distance pipe 1,2,3]

<0.0> Determines the manually measured distances from the top surfaces of the measuring pipes to the liquid (product) level in the tank. These values are measured at reference conditions, without any snow or ice on the roof.

[Averaging constant filter]

<90> Determines the value for the averaging constant in the RIC offset filter on the GPU level, and determines the weight of the (new) measured/calculated offset.

[Minimum level] <0.0> Determines the minimum innage above which the roof immersion compensation can be active.

[Accept reference RIC]

This command should be issued in a stable floating roof situation when no snow and ice are on top of the floating roof. After this command measured levels of the probes are copied into the reference levels of the roof immersion sensors.

[Sensor 1,2,3 delta x1,x2,x3]

Shows the values of the probe reference levels minus the actual measured probe values, assuming the probes are measuring an innage value.

[Sensors delta x aver]

Shows the arithmetic mean of the three individual distances from the top measuring pipes to the surface level.

[Reference level sensor 1,2,3]

Shows the reference level (innage) of the roof immersion sensors. It is the measured level of the probe in normal, stable conditions without any snow or ice on the roof. These levels are set after the use of the “Accept reference RIC” command.

COMMISSIONING


Miscellaneous

Name Value Range

Default Value Explanation

[Functional licensed options]

<32 times false> Shows which fields (and thus related options) are enabled/set to true.

Field 01: Density option

COMMISSIONING


Relay contacts (FII-DO) 7.3.6.1 Introduction

The Field Interface Instrument - Digital Output (FII-DO) board has 4 software-controlled, electromechanical relays; see Figure 7-7.

Note: only two relays, the low rated or high rated, are used not all 4 together.

Figure 7-7 The relays and LEDs on the FII-DO board

These relays are allocated to FlexConn functions as shown below:

Function Number Function 1 Relay 1

2 Relay 2

3 Relay 3

4 Relay 4

The relays have output status read-back lines.

With jumpers, the relays can individually be set to Normally Open (NO) or Normally Closed (NC).

COMMISSIONING


In addition to the board’s [Health] LED LE1, the LEDs LE2 and LE3 are available (see Figure 7-7). They can be associated to a relay, by setting the [LED Association] entity.

☛ For a fail-safe level application, continue with section 7.3.6.10.

7.3.6.2 Operation Mode

The FII-DO can operate in one of two modes: [Alarm Mode] and [Fallback Mode]. This is controlled by the [Operation Mode] entity.

Fallback Mode is not implemented yet.

☛ Set the [Operation Mode] entity to [Alarm Mode].

7.3.6.3 Relay Configuration 7.3.6.3.1 Jumper Settings

At installation, each individual relay contact was configured as required with the hardware jumpers JPx0, where x = Relay 1 to 4 respectively. See Figure 7-8.

Figure 7-8 The relays’ hardware jumpers

NOTE: In the Commissioning stage, no jumper setting can be changed without breaking the compartment screw sealing.

COMMISSIONING


7.3.6.3.2 Relay Mode

Each individual relay can be set to be energized or de-energized during operation, by setting the [Relay Mode] entity to <Energized> or <De-energized> respectively.

If the [Relay Mode] entity is set to <Energized>, the relay coil will be energized when the relay state is <Deactivated>, and the relay coil will be de-energized when the relay state is <Activated>.

If the [Relay Mode] entity is set to <De-Energized>, the relay coil will be de-energized when the relay state is <Deactivated>, and the relay coil will be energized when the relay state is <Activated>.

The <Energized> option is used for fail-safe operation whereas the <De-Energized> option is used for non-fail-safe operation.

☛ Set each individual relay to the required configuration, by selecting the proper entities. See also next overview (fail-safe configuration is coloured).

Physically Configured Relay Mode Relay State

Physical Result

Normally Open (NO)

De-Energized Activated Closed

Deactivated Open

Energized Activated Open

Deactivated Closed

Normally Closed (NC)

De-Energized Activated Open

Deactivated Closed

Energized Activated Closed

Deactivated Open

COMMISSIONING


7.3.6.4 Alarm Mode

Each individual relay can operate in one out of three modes, by setting the [Alarm Mode] entity to either [PV Monitor], [Remote Control], or [Not In Use].

7.3.6.4.1 PV Monitor

In [PV Monitor] mode, each individual FII-DO-relay unit can monitor the Primary Value (PV) or Secondary Value (SV) of another board connected to the CAN bus, and either activate or deactivate the associated relay if a certain condition is <True> or <False>.

☛ If [Remote Control] or [Not In Use] mode must be selected, skip to section 7.3.6.4.4 and 0 respectively.

☛ From the [Alarm Mode] menu, select [PV Monitor].

☛ Select [Monitor Board ID], set proper value.

☛ Select [Monitor Board Instance], set proper value.

☛ Select [Monitor Function Instance], set proper value.

☛ Select [Monitor Source], select either <PV> or <SV>, as desired.

The [Monitor Board ID], [Monitor Board Instance], and [Monitor Function Instance] entities determine the location of the entity to be scanned.

The behavior of each individual relay in PV Monitor mode is further controlled by the [Monitor Mode] and the [Status Behavior] entities; see next.

7.3.6.4.2 Monitor Mode

The [Monitor Mode] entity can either be set to [Remote] or [Local].

If the [Monitor Mode] is set to [Remote], the alarm status of the scanned PV or SV is monitored. The alarm status is compared against the value set in the [Remote Threshold Source] entity. The [Remote Threshold Source] entity can be set to <HH>, <HA>, <LA>, or <LL>.

Example: If the [Remote Threshold Source] is set to <HH> and a High High Alarm occurs, the relay will be activated. It will not be activated by any other alarms.

COMMISSIONING


☛ If [Local] [Monitor Mode] is to be set, skip to next bullet ().

☛ From the [Monitor Mode], select [Remote].

☛ Select [Remote Threshold Source], set desired value.

If the [Monitor Mode] is set to [Local], the scanned PV or SV value is compared against the value set in the [Threshold] entity. The behavior is modified by the [Threshold Mode] and the [Hysteresis] entities. The [Threshold Mode] entity can be set to either <Treat as HA> or <Treat as LA>. If the [Threshold Mode] entity is set to <Treat as HA>, the relay is activated if the scanned PV or SV is greater than or equal to the [Threshold] entity value, and the relay is deactivated if the scanned PV or SV is less than the [Threshold] entity value minus the [Hysteresis] entity value. If the [Threshold Mode] entity is set to <Treat as LA>, the relay is activated if the scanned PV or SV is greater than or equal to the [Threshold] entity value, and the relay is deactivated if the scanned PV or SV is less than the [Threshold] entity value plus the [Hysteresis] entity value.

☛ From the [Monitor Mode], select [Local].

☛ Select [Threshold Mode], and choose either <Treat as HA> or <Treat as LA>.

☛ Select [Hysteresis], set desired value.

7.3.6.4.3 Status Behavior

The Status Behavior entity determines what happens to the relay if the health of the scanned PV or SV differs from Good. The [Status Behavior] should be set to one of the following options: <BAD>, <BAD-UNCERTAIN>, or <Not Used>.

If the [Status Behavior] is set to <BAD>, and the scanned PV or SV health is Bad, the respective relay will be activated.

If the [Status Behavior] is set to <BAD-UNCERTAIN>, and the scanned PV or SV health is Bad or Uncertain, the respective relay will be activated.

COMMISSIONING


If the [Status Behavior] is set to <Not Used>, the respective relay will not be activated if the scanned PV or SV health is Bad or Uncertain.

☛ Set the [Status Behavior] entity either to <BAD>, <BAD-UNCERTAIN>, or <Not Used>.

NOTE:This behavior takes priority over the [Remote] or [Local] monitoring. For example: If the [Status Behavior] is set to <BAD>, and the scanned PV or SV health is Bad, the respective relay will be activated regardless of the [Monitor Mode] entity settings. The [Remote] or [Local] option PV or SV checks will then not affect the relay status.

7.3.6.4.4 Remote Control

In [Remote Control] mode, each individual relay can directly be activated or deactivated, by sending an !Activate! respectively a !Deactivate! command via the CAN bus.

The behavior of each individual relay is further controlled by the [Remote Control] mode entity, which can be set to either <Restricted> or <Not Restricted>.

If the [Remote Control] mode entity is set to <Not Restricted>, any source can be used to control the relay with an !Activate! or a !Deactivate! command.

If the [Remote Control] mode entity is set to <Restricted>, the relay can only be controlled by the source that matches the values set in the [Control Board ID], the [Control Board Instance], and the [Control Function Instance].

☛ From the [Remote Control] mode menu, select either <Restricted> or <Not Restricted>.

☛ If Not Restricted was selected, skip to 0.

☛ Select [Control Board ID], set proper value.

☛ Select [Control Board Instance], set proper value.

☛ Select [Control Function Instance], set proper value.

COMMISSIONING


7.3.6.4.5 Not in Use

If an individual relay is not required in a particular application, the [Alarm Mode] entity must be set to <Not In Use>.

Example: If a particular application requires only two relays to be used, say relay 1 and 2, then for relay 3 and 4 the [Alarm Mode] entities must be set to <Not In Use>.

☛ For the FII-DO relays not used within the application, set the [Alarm Mode] entities to <Not In Use>.

7.3.6.5 Commands

The following commands can be given to the FII-DO:

Activate

Deactivate

Acknowledge

7.3.6.5.1 Activate

The !Activate! command will cause the specified relay to become <Activated>. This command is only available in [Remote Control] mode; see 7.3.6.4.4.

The !Activate! command behavior is modified by the [Time Setting] entity. If the [Time Setting] entity is set to zero, the relay will stay permanently activated until a !Deactivate! command is given.

If the [Time Setting] entity is set to a value other than zero, the relay will be activated for a time in seconds equal to the value set in the [Time Setting] entity, then deactivated. During the period the relay is activated, the relay state will be !Time Setting Active!. This is useful for site commissioning.

☛ For each relay, set the [Time Setting] entity to the desired value.

7.3.6.5.2 Deactivate

The !Deactivate! command will cause the specified relay to become <Deactivated>. This command is only available in [Remote Control] mode; see 7.3.6.4.4.

COMMISSIONING


7.3.6.5.3 Acknowledge

The !Acknowledge! command will cause the specified relay to be physically deactivated, but the relay status will be set to !Acknowledged!. This command is only available in [PV Monitor] mode; see 7.3.6.4.1. This command can only be given when the concerned relay has already been activated.

For example, this command is useful if the relay is connected to an alarm system. The alarm can be silenced by the command, but it is still possible to determine if an alarm has occurred. When the alarm condition is then removed, the relay state will become deactivated, and normal operation will resume.

7.3.6.6 LED Association

Depending on the value set in the [LED Association] entity, the 4 individual relays on the FII-DO board can be associated with one out of 2 LEDs, LE2 or LE3 (see Figure 7-7).

The associated LED will be ON when the relay state is <Activated>, and the LED will be OFF when the relay state is <Deactivated>.

NOTE: The LEDs do not indicate the physical relay state (coil state or contacts state), as this depends on the software settings and the physical settings (jumper), see Relay Configuration 7.3.6.3.

☛Set the value of the [LED Association] entity as desired (optional). For an example, see table below.

LED Association LED Number Relay Number 1 + 2 LE2 1

LE3 2

3 + 4 LE2 3

LE3 4

7.3.6.7 Terminal Allocation

Terminal Number Name Function 14 Ry1_a Relay 1 Common

15 Ry1_b Relay 1 NO or NC*

16 Ry2_a Relay 2 Common






*) See jumper settings, section 7.3.6.3.1

COMMISSIONING


7.3.6.8 Commissioned Entities

☛By using the table below, make sure all entities are commissioned.

The [Commissioned] entity will display either <True> if the function is commissioned or <False> if the function is not commissioned. To commission the function, the entities must be set in accordance with the table below.

Operation Mode

Alarm Mode

Remote Control Mode

Parameters

Commissioned

Alarm Mode Remote Control

Restricted [Control Board ID] >=1 and =255 [Control Board Instance] >=0 and <=7 [Control Function Instance] >=1 and <=15 [Time Setting] = 0

<True>

[Control Board ID] <1 or >255 [Control Board Instance] <0 and >7 [Control Function Instance] <1 and >15 [Time Setting] ≠ 0

<False>

Not Restricted

[Time Setting] = 0 <True>

[Time Setting] ≠ 0 <False> PV Monitor Remote [Monitor Board ID] >=1 and <=255

[Monitor Board Instance] >=0 and <=7 [Monitor Function Instance] >=1 and <=15 [Time Setting] = 0

<True>

[Monitor Board ID] <1 or >255 [Monitor Board Instance] <0 and >7 [Monitor Function Instance] <1 and >15 [Time Setting] ≠ 0

<False>

Local [Monitor Board ID] >=1 and <=255 [Monitor Board Instance] >=0 and <=7 [Monitor Function Instance] >=1 and <=15 [Time Setting] = 0 [Threshold] = value entered [Hysteresis] = value entered

<True>

[Monitor Board ID] <1 or >255 [Monitor Board Instance] <0 and >7 [Monitor Function Instance] <1 and >15 [Time Setting] ≠ 0 [Threshold] = value entered [Hysteresis] = value entered

<False>

Not In Use N/A N/A <True>

Fallback Mode

N/A N/A N/A <False>

COMMISSIONING


7.3.6.9 Board Commissioned Entity

The [Board Commissioned] entity will display either <True> if all functions are commissioned or <False> if any of the functions are not commissioned.

☛If the [Board Commissioned] entity displays <False>, check each function parameter again. Use the table from 7.3.6.8.

7.3.6.10 Fail-safe Level Application

Following steps include all commissioning-aspects settings for the Fail-safe level application.

☛The corresponding jumper of the concerned relay must be in the Normally Open (NO) state (= default setting).

NOTE: In the Commissioning stage, no jumper setting can be changed without breaking the compartment screw sealing.

☛Set [Operation Mode] to [Alarm Mode].

☛Set [Relay Mode] to <Energized>.

☛Set [Alarm Mode] to [PV Monitor].

☛Set [Monitor Board ID] to <board id> of product-level board.

☛Set [Monitor Board Instance] to <board instance> of related product-level board.

Set [Monitor Function Instance] to <function instance> of related product-level board.

☛Set [Monitor Source] to <PV>.

☛Set [Monitor Mode] to [Remote].

☛Set [Remote Threshold Source] to <HH>, <HA>, <LA>, or <LL>.

☛Set corresponding alarm setting of the related product-level board.

☛Set [Status Behavior] to <BAD-UNCERTAIN>

COMMISSIONING


FCI-HRT, HART master


The Field Communication Instrument - HART (FCI-HRT) board is a module that communicates with HART SmartView.

The FCI-HRT board is a HART®1 master module that enables hybrid- signal (both analog + digital) communication between the FlexConn instrument and a HART sensor and VITO-data processor module, which calculates average product- and Vapour temperatures, and optionally a water level.

Figure 7-9 The FCI-HRT board

The HART protocol is a bi-directional master-slave communication protocol, which is used to communicate between intelligent field instruments and host systems.

The FCI-HRT board has a planar transformer for galvanic isolation from the HART bus. See Figure 7-9.

LED LE1 is the board’s [Health] LED. LEDs LE2 and LE3 will be flashing to indicate activity on the HART bus. LE2 indicates data is being transmitted (Tx), LE3 indicates data is being received (Rx).

COMMISSIONING


With the HART protocol, an analog 4-20 mA signal can be combined with a digital Frequency Shift Keying (FSK) signal. See Figure 7-10

Figure 7-10 The analog and digital signals within the HART® communication

7.3.7.2 Software Description

The FCI-HT board, being a functional module of the 954 SmartServo FlexLine, contains embedded software which enables it to collect data input from sensors via both the HART bus and the FlexConn CAN bus.

Moreover the FCI-HT module can calculate the HIMS1 product density. The main function of the FCI-HT software is to measure HIMS product

density, by connecting the FCI-HT board via the HART bus to 1 or 2

pressure sensors, and via the FlexConn bus to a product level and a water level sensor.

To measure product density, the needed standard system configuration is:

HART pressure sensor P1 (product pressure)

HART pressure sensor P3 (Vapour pressure)

Product level scanned from a FlexConn board (e.g. TII-XR)

Water level scanned from a FlexConn board (e.g. FII-VT)

For tanks that are free venting to the atmosphere or floating-roof tanks, P3 pressure is not required. The water level sensor is also optional.

1. Hybrid Inventory Measurement System

COMMISSIONING


For HIMS density measurement system diagrams, see Figure 7-11 and Figure 7-12

Figure 7-11 Standard HIMS density measurement system diagram

Figure 7-12 Floating-roof or free-venting tank HIMS density measurement system diagram

COMMISSIONING


As an alternative function, the FCI-HT board also allows the connection of up to 5 generic HART sensors operating in multi-drop digital mode or one generic HART sensor operating in analog mode.

In the multi-drop digital mode situation, one or two of the generic HART sensors can be [P1 Pressure] or [P3 Pressure], providing product pressure and Vapour pressure respectively, but no HIMS density calculation will be available.

The HART sensors and HIMS density measurement are allocated to a function number in the FCI-HT software. See table below.

FlexConn Function Device Type Function 1 [P1 Pressure]

Function 2 [P3 Pressure]

Function 3 [Distance]

Function 4 [Temperature]

Function 5 [Pressure]

Function 6 [Density]

Function 7 [Other]

Function 8 [HIMS Density]

Table 7-1 FlexConn function allocation

Function 1 is exclusively reserved for P1 pressure, Function 2 is exclusively reserved for P3 pressure, and Function 8 is exclusively reserved for HIMS density calculation.

Only one of each type of HART device can be allocated to a function. Therefore, this limits the number of HART devices of each type that can be fitted.

Example 1

4 HART pressure devices and 1 temperature device can be connected.

P1 pressure device allocated to Function 1

P3 pressure device allocated to Function 2

one pressure device allocated to Function 5

one pressure device allocated to Function 7

the temperature device allocated to Function 4

COMMISSIONING


Example 2

2 HART density devices and 1 distance device can be connected.

density device 1 allocated to Function 6

density device 2 allocated to Function 7

the distance device allocated to Function 3

Figure 7-13 Alternate system diagram multi-drop digital mode

COMMISSIONING


In analog mode, the connected HART device will be allocated to Function 1 through 7, depending on the type of HART device connected.

Figure 7-14 Alternate system diagram multi-drop digital mode

COMMISSIONING


7.3.7.3 Software Specifications

7.3.7.3.1 General

The main function of the FCI-HT software is to measure HIMS product density, by connecting the FCI-HT board via the HART bus to 2 pressure sensors (P1 and P3), and via the FlexConn bus to a product level sensor and an optional water level sensor.

The alternative function is to connect up to 5 generic HART devices operating in multi-drop digital mode or 1 generic HART device operating in analog mode.

The FCI-HT software only supports HART devices with the following addresses.

HART Address Function 00 Reserved for HART device in analog mode

01 Reserved for P1 pressure sensor

02 N/A Reserved for future use

03 Reserved for P3 pressure sensor

04 HART generic sensor

HART Address Function 05 HART generic sensor











Table 7-2 Accepted HART addresses

☛ Before proceeding with commissioning, first check the maximum start-up current of all connected HART devices.

☛ Make sure the HART address of the installed device(s) are in accordance with Table 7-2 Accepted HART addresses.

COMMISSIONING


7.3.7.3.2 P1 Pressure

The FCI-HT software only accepts the Primary Value of a P1 pressure HART device in SI units kilo Pascals (kPa).

☛ Make sure the P1 pressure HART device is configured to output data in kilo Pascals (kPa). If not, correctly configure as yet, by using an appropriate HART configuration tool.

Sensor Type Accepted HART

PV Unit Abbreviation HART PV Unit Code

P1 Pressure Kilo Pascal kPa 12

Table 7-3 Accepted PV unit for a P1 HART device

NOTE: The Secondary and Tertiary values of a P1 pressure HART device may be any units.

The PV of the P1 pressure HART device is read and converted into SI Units Pascals (Pa) within the FlexConn function PV.

The value is filtered, and the filtering factor depends on the value set in the entity [P1 Integration time]. A higher value gives more filtering, and a lower value gives less filtering.

The correction factor stored in the [P1 PV offset] entity is then subtracted from the filtered value. If the [P1 PV offset] entity = 0 no offset is applied.

Depending on the [PV selected type] entity, the P1 pressure can be displayed as either absolute pressure or relative pressure.

PV Unit Type Display Unit Type PV selected type P1 Pressure Absolute 1

Relative 2

Table 7-4 P1 pressure displayed unit types

If Relative pressure is selected, the value stored in the [Ambient Air Pressure] entity is added to the measured pressure. If Absolute pressure is selected, no factor is added. The final result is available in the [Primary Value] entity.

NOTE: Absolute pressure is used in the density calculation; the relative pressure is only displayed in P1 [Primary Value].

COMMISSIONING


For the FCI-HT software to differentiate between a HART device malfunction and a HART device not actually installed, P1 pressure has the entity [P1 Installed] which must be set to either <Installed> if a P1 pressure HART device is actually fitted or <Not Installed> if a P1 pressure HART device is not actually fitted.

The Secondary and Tertiary values of a P1 pressure HART device are not converted, and they are simply translated from the HART device to the FlexConn environment.

7.3.7.3.3 P3 Pressure

The FCI-HT software only accepts the Primary Value of a P3 pressure

HART device in SI units kilo Pascals (kPa).

☛ Make sure the P3 pressure HART device is configured to output data in kilo Pascals (kPa). If not, correctly configure as yet, by using an appropriate HART configuration tool.

Sensor Type Accepted HART

PV Unit Abbreviation HART PV Unit Code

P3 Pressure Kilo Pascal kPa 12

Table 7-5 Accepted PV unit for a P3 HART device

NOTE: The Secondary and Tertiary values of a P3 pressure HART device may be any units.

The PV of the P3 pressure HART device is read and converted into SI Units Pascals (Pa) within the FlexConn function PV.

The value is filtered, and the filtering factor depends on the value set in the entity [P3 Integration time]. A higher value gives more filtering, and a lower value gives less filtering.

The correction factor stored in the [P3 PV offset] entity is then subtracted from the filtered value. If the [P3 PV offset] entity = 0 no offset is applied.

Depending on the [PV selected type] entity, the P3 pressure can be displayed as either absolute pressure or relative pressure.

PV Unit Type Display Unit Type PV selected type P3 Pressure Absolute 1

Relative 2

Table 7-6 P3 pressure displayed unit types

COMMISSIONING


If Relative pressure is selected, the value stored in the [Ambient Air Pressure] entity is added to the measured pressure. If Absolute pressure is selected, no factor is added. The final result is available in the [Primary Value] entity.

NOTE: Absolute pressure is used in the density calculation; the relative pressure is only displayed in P3 [Primary Value].

For the FCI-HT software to differentiate between a HART device malfunction and a HART device not actually installed, P3 pressure has the entity [P3 Installed] which must be set to either <Installed> if a P3 pressure HART device is actually fitted or <Not Installed> if a P3 pressure HART device is not actually fitted. For example, in the case of free- venting tanks, P3 would usually not be installed.

If the P3 pressure status is <Good Actual>, the P3 pressure value is also stored in memory in the [Last Valid P3] entity, to allow recovery from a power-down situation when a P3 pressure is not available.

If the measured P3 pressure is invalid (e.g. HART scan error), the software will check the [P3 Installed] entity to determine if P3 is actually fitted. If P3 is fitted, the software will check for a [Manual P3 Pressure] entity value to be entered. If no manual P3 pressure value is entered, the [Last Valid P3] is used in the density calculation. If no [Last Valid P3] is available, an error will be reported.

If P3 pressure is not installed - in the case of free-venting tanks - a default value of 0.0 for P3 pressure is used for density calculations.

The Secondary and Tertiary values of a P3 pressure HART device are not converted, and they are simply translated from the HART device to the FlexConn environment.

7.3.7.3.4 HIMS Density

To make HIMS density calculation possible, the relevant entity values must be available. See also Figure 7-15

☛ Read also the Instruction Manual HIMS pressure measurement.

☛ Enter the appropriate values into the following entities:

• [Distance P1 to Zero Level]

• [Distance P3 to Zero Level]

• [Hydrostatic Deformation Level]

• [Hydrostatic Deformation Factor]

• [Local Gravity]

COMMISSIONING


• [Minimum HIMS Level]

• [HIMS Level Hysteresis]

• [Ambient Air Density]

• [Tank Vapour Density]

Figure 7-15 HIMS configuration principle

To calculate HIMS density, the following valid data must be available:

P1 pressure

P3 pressure

Product level

Water level (optional)

COMMISSIONING


7.3.7.4 Average Temperature & Water Level Measurement 7.3.7.4.1 Introduction

The Field Interface Instrument - VITO1 (FII-VT) board is a VITO-data processor module, which calculates average product- and Vapour temperatures, and optionally a water level

Figure 7-16 The FII-VT board with its planar transformer

By using the HART® protocol, the FII-VT module can be connected to one VITO-interface which in turn is connected to a probe for product temperature, Vapour temperature, water level, or a combination of these.

The FII-VT board has a planar transformer for galvanic isolation from the HART bus. See Figure 7-16.


1. Versatile In-Tank Observer

COMMISSIONING


7.3.7.4.2 VITO Interface Types

For temperature and/or water level measurement, a proper VITO probe must be connected to the FII-VT module, using a VITO interface.

There are 3 VITO interface types:

762 VITO MTT interface for 16-spot temperature measurement (thermocouple principle) and optionally a water bottom measurement

762 VITO LT interface for 9-spot temperature measurement (thermocouple principle) and optionally a water bottom measurement

762 VITO MRT interface for Multiple Resistance Thermometer and multi-spot (resistance variation principle) measurement

7.3.7.4.3 Commissioning Commissioning Parameters for MTT/LT Probes

The following 9 configurations are possible:

Enraf Model VITO Type Description 764C MTT Temperature probe lowest spot next to Pt100, no water probe

764D lowest spot below Pt100, no water probe

766C MTT Combi probe lowest spot next to Pt100, combined with water probe

766D lowest spot below Pt100, combined with water probe

767C LT Temperature probe lowest spot next to Pt100, no water probe

767D lowest spot below Pt100, no water probe

768C LT Combi probe lowest spot next to Pt100, combined with water probe

768D lowest spot below Pt100, combined with water probe

765 Water probe water probe only

These models are depicted in Figure 7-17 and Figure 7-18

COMMISSIONING


Figure 7-17 Tank and temperature probe data (1)

COMMISSIONING


Figure 7-18 Tank and temperature probe data (2)

COMMISSIONING


Product Temperature

☛ The following entities must be set by Engauge or HART SmartView for a correct functioning of the FII-VT module in an instrument.

NOTE: Using Engauge, following entities are set within the Engauge Product temperature tab.

Name Explanation Value Range Default [Lowest element offset] The distance from tank zero

till the lowest element position in the temperature probe

floating point number: <-x.x .. +x.x>

<80.0>

[Sensor length] The distance from the Pt100 position till the highest element position


<80.0>

The following entities can be set by Engauge or HART SmartView for a correct functioning of the FII-VT module in an instrument.

☛ Check each entity for its correctness.

Name Explanation Value Range Default [Product immersion depth] The minimum required

distance of the product level above an element before it is taken into account in the average product temperature calculation


<0.5>

[Hysteresis] The distance for a hysteresis mechanism around the switching point of the elements that are taken into account in the calculation


<0.1>

[High High alarm] [High Alarm] [Low Alarm] [Low Low alarm]

4 thresholds for activating a related alarm status in the Primary Value


<+1.0E22>

COMMISSIONING


Name Explanation Value Range Default [Alarm test enable]

Enables (if activated, see next listed entity) the simulation of one of the 4 alarms for a minute, by simulating the actual measured Primary Value is below or above the alarm threshold.

<enable> <disable>

<disable>

[Alarm test]

Activates and selects at the same time the Alarm test (if enabled with the [Alarm test enable] listed before, and the 4 alarm thresholds are properly set).

[No Alarm] [High High alarm] [High Alarm] [Low Alarm] [Low Low alarm]

<No Alarm>

[Element wiring] Used for excluding an element from the average product temperature calculation.

16 characters A non-zero (≠ 0) character at position x results in element x being excluded from calculation.

<0000000000000000>

[Function identification] The current module’s function name. This function is visible on the HART SmartView display.

13 characters <Product temp.>

Vapour Temperature NOTE: Using Engauge, following entities are set within the Engauge Vapour temperature tab. Some Vapour temperature settings are shared with Product temperature settings.



Name Explanation Value Range Default [Gas immersion depth] The minimum required

distance below an element before it is taken into account in the average Vapour temperature calculation


<0.5>




<+1.0E22>

COMMISSIONING


Name Explanation Value Range Default [Alarm test enable]


<enable> <disable>

<disable>

[Alarm test]



<No Alarm>

[Function identification]

The current module’s function name. This function is visible on the HART SmartView display.

13 characters <Vapour temp.>

Water Level (for 766/768 Combi probes and 765 Water probe only)


Name Explanation Value Range Default [Maximum water capacity] The maximum capacity

when the probe is fully submerged in water (in pF)


<20000>

[Minimum water capacity] The minimum capacity when the probe is not submerged in water (in pF)


<20000>

[Water probe bottom position] The offset to the water probe zero point in relation with the tank zero point


<80>

[Upper reference level] The distance from tank zero point to upper reference point; is used for water ullage calculation


<80>

COMMISSIONING


☛ The following entities can be set by Engauge or HART SmartView for a correct functioning of the FII-VT module in an instrument.

Name Explanation Value Range Default [Water probe length] The length of a water probe floating point number:

<-x.x .. +x.x> <0.5>

[High High alarm]� [High Alarm]� [Low Alarm]� [Low Low alarm]


floating point numbers: <-x.x .. +x.x>

<+1.0E22>

[Alarm test enable]


<enable> <disable>

<disable>

[Alarm test]

Activates and selects at the same time the Alarm test (if enabled with the [Alarm test enable] listed before, and the4 alarm thresholds are properly set).


<No Alarm>

[Function identification] The current module’s function name. This function is visible on the HART SmartView display.

13 characters <Water level>

COMMISSIONING


7.3.7.4.4 Commissioning Parameters for MRT or RTD

Enraf Model VITO Type Description MRT Multiple Resistance Thermometer MRT with up to 13 temperature elements with

one spot element

RTD 3-spot Resistance Temperature Detector

1..3 RTD spots in a 3-wire connection

multi-spot Resistance Temperature Detector

1..14 RTD spots in a 2-wire connection

See Figure 7-19 and Figure 7-20

Figure 7-19 Resistance Temperature Detector (RTD) elements positions

COMMISSIONING


Figure 7-20 Multiple Resistance Thermometer (MRT) parameters

COMMISSIONING


Product Temperature


NOTE: Using Engauge, following entities are set within the Engauge Product temperature tab.

RTD 3 spots (see Figure 7-19 left side)

Name Explanation Value Range Default [Element type] The supported element

type is: SPL 3 characters <SPL>

<--->

[Number of elements] The number of elements a RTD probe has

<1 .. 3> <0>

[Lowest element offset] The distance from tank zero till the lowest position of the multi-RTD probe. So not used for the 3-wire version and it must be 0.


MUST BE <0.0>

<80.0>

[RTD element positions] The positions of the RTDs from tank zero level

3 floating point numbers: <-x.x .. +x.x> Note: Only actually used elements to be entered.

<0,0,0>

Multi RTD probe (see Figure 7-19 right side)

Name Explanation Value Range Default [Element type] The supported element

type is : SPL 3 characters <SPL>

<--->

[Number of elements] The number of elements a RTD probe has

<1 .. 14> <0>

[Lowest element offset] The distance from tank zero till the lowest position of the multi-RTD probe


<80.0>

[RTD element positions]

The positions of the RTDs from the lowest position of the probe. So not tank zero level!

14 floating point numbers: <-x.x .. +x.x> Note: Only actually used elements to be entered.

<0,0,0,0,0,0,0,0,0,0,0,0,0,0>

COMMISSIONING


• MRT (see Figure 7-20)

Name Explanation Value Range Default [Element type] See TABLE below. 3 characters

<RCB> <RCN> <RCS> <QCB> <QCN> <QCS>

<--->

[Number of elements] The number of elements (resistors) an MRT probe has

<1 .. 14> <0>

[Lowest element offset] The distance from tank zero till the lowest position of the MRT probe


<80.0>

[MRT element length] if MRT length table = <T>

The lengths of the MRTs including anchor eye

14 floating point numbers:<-x.x .. +x.x>

<0,0,0,0,0,0,0,0,0,0,0,0,0,0>

[MRT length table]

Specifies whether a fixed range of MRT resistors is used (= <F>) or user- configured lengths (= <T>).

Fixed lengths are: 0.25 / 0.65 / 1.25 / 1.95 / 2.85 / 4.15 / 5.65 / 7.35 / 9.25 / 11.65 / 14.65 / 18.45 / 22.95 / 29.65

1 character <F> <T>

<F>

R.. = an MRT without spot element

Q.. = an MRT with spot element

.CB Rth = 90.2935 + T x 0.38826 (- 100 through + 280 °C)

.CN Rth = 90.4778 + T x 0.38090 (- 100 through + 280 °C)

.CS Rth = 90.5000 + T x 0.38730 (- 100 through + 280 °C)

Table 7-7 Element type definitions

COMMISSIONING





product level distance above an element before this element is taken into account in the average product temperature calculation


<0.5>

[Hysteresis] This is a hysteresis mechanism distance around the switching points of the elements that are taken into account in the calculation.


<0.1>




<1.0E22>

[Alarm test enable]


<enable> <disable>

<disable>

[Alarm test]



<No Alarm>




COMMISSIONING


Vapour Temperature

NOTE: Using Engauge, following entities are set within the Engauge Vapour temperature tab. Some Vapour temperature settings are shared with Product temperature settings.



Name Explanation Value Range Default [Gas immersion depth] The minimum required

distance below an element before it is taken into account in the average Vapour temperature calculation


<0.5>




<+1.0E22>

[Alarm test enable]


<enable> <disable>

<disable>

[Alarm test]



<No Alarm>




COMMISSIONING


7.3.7.4.5 Commissioning Parameters for the 765 VITO Water Probe

For the entities to be set for the stand-alone 765 VITO water probe (see Figure 7-21).

Figure 7-21 The model 765 VITO water probe

COMMISSIONING


Water Level


Name Explanation Value Range Default [Maximum water capacity] The maximum capacity

when the probe is fully submerged in water (in pF)


<20000>

[Minimum water capacity] The minimum capacity when the probe is not submerged in water (in pF)


<20000>

[Water probe bottom position] The offset to the water probe zero point in relation with the tank zero point


<80>

[Upper reference level] The distance from tank zero point to upper reference point; is used for water ullage calculation


<80>

☛ The following entities can be set by Engauge or HART SmartView for a correct functioning of the FII-VT module in an instrument.

Name Explanation Value Range Default [Water probe length] The length of the 765 VITO

water probe floating point number: <-x.x .. +x.x>

<0.5>




<+1.0E22>

[Alarm test enable]


<enable> <disable>

<disable>

COMMISSIONING


Name Explanation Value Range Default [Alarm test]


[No Alarm] [High High alarm] [High Alarm] [Low Alarm] [L L l ]

<No Alarm>



13 characters <Water level>

7.3.7.4.6 Commissioning Check

☛ After having checked/set all before listed entities, make sure

the [Board Commissioned], the [Product temperature Commissioned], the [Vapour temperature Commissioned], and - if applicable - the [Water level Commissioned] entities are <True>;

the [Board Health], the [Product temperature Health], the [Vapour temperature Health], and - if applicable - the [Water level Health] entities are <GOOD>.

COMMISSIONING


Average Temperature Measurement (FII-RTD)


The Field Interface Instrument - Resistance Temperature Detector (FII- RTD) board is a sensor module for the instrument (gauge) and calculates average product, Vapour- and ambient temperatures.

For accomplishing this, RTDs or MRTs must be directly connected to the FII-RTD module

Figure 7-22 The FII-RTD board

There are four possible configurations to calculate the average product, Vapour, and ambient temperatures using the FII-RTD board.

1 or 2 RTDs in a 3-wire configuration.

1 or 2 RTDs in a 4-wire configuration.

2 through 6 RTDs as a probe called MPT. It should contain 1 wire per RTD + 2 common wires for all RTDs.

2 through 6 MRTs as a probe. It should contain 1 wire per MRT + 2 common wires for all MRTs.

NOTE: Only in RTD 3-wire or 4-wire configurations ambient temperature calculation is possible.

COMMISSIONING


7.3.8.2 Some Important Settings

The FII-RTD can be tailored to the need of the customer by a lot of settings. See section 7 Commissioning

Some important settings of the FII-RTD in Board Specific tab are listed below.

Setting Remarks [Measurement type] ″ MPT

″ MRT ″ Mtt ″ No measurement type ″ RTD 3-wire ″ RTD 4-wire

[Element type] ″ Cu100 ″ Cu90 Beacon ″ Cu90 Enraf ″ Cu90 Nulectrohms ″ Ni191 ″ No element type ″ Pt100 large ″ Pt100 small ″ PtCu100 ″ Sangamo MRT ″ Sangamo spot ″ Thermocouple

[RTD configuration] • RTD1 in tank • RTD1 + RTD2 in tank • RTD1 in tank + RTD2 ambient • RTD1 ambient ″ No RTD configuration ″ RTD1 in tank ″ RTD1 in tank + RTD2 ambient

[Gauge temperature scale] Can be: • IPTS-68 • ITS-90

[Lowest element offset] This is the distance from tank bottom till lowest element position

[Number of elements] Can be 1..6

[MPT sensor length] -

COMMISSIONING


7.3.8.3 Some Important Features

Temperature calculations can be:

o Standard (just simple averaging the spot temperatures).

o Enhanced (averaging the spot temperatures and taking into account the contribution of each spot in respect to its immersion).

o Custom (as standard but then giving it a weighing factor).

o A temperature-range check can be turned on. In this case, if spot elements are out of range, a fail state results (if not skipped), see Figure 7-23.

Figure 7-23 Temperature range check feature

• A median filter can be turn on or off, which eliminates spikes of each individual calculated spot temperature.

• An averaging constant filter can be turned on or off, which takes a certain part of the previous calculated average temperature and a certain part of the new calculated temperature into account.

• Low element usage with following possible sub-settings can be applied: ″ No exclusion ″ Static exclusion ″ Dynamic exclusion

These settings are then to be refined further with: ″ Exclude zone ″ Smoothing level ″ Low element behaviour

COMMISSIONING


See Figure 7-24.

Low element usage

NO EXCLUSION (default)

RTDs and MPT

STATIC EXCLUSION

MPTs > = 2 elements

DYNAMIC EXCLUSION

MPTs > = 3 elements

Product level

Product level

Product level

> lowest element

<= lowest

element

>

Tempe rature

element exclude

zone

AND > T 2 pos

>

Tempe rature

element exclude

zone AND

< = T 2 pos

<=

Tempe rature

element exclude

zone

> smoothing

level

<= smoothing

level AND

> T2 pos

<=

T 2 pos

AND

> T1 pos

<= T 1 pos

all submerged elements

low- element behaviour


with T1

excluded


temperature fail


with T1

excluded

Smoothing (overrules selected

temperature calculation method)

use T1


FAIL

LAST

VAL

ID

USE

T1

FAIL

LAST

VAL

ID

USE

T2

FAIL

LAST

VAL

ID

USE

T1

T1 pos < Temperature element

exclude zone < T2 pos

Temperature element exclude zone default = 1 m

T2 pos < Smoothing level < T3 pos

Smoothing level default = 0 m

Figure 7-24 Low element usage settings overview

COMMISSIONING


• W&M Sealing1: This board can be electronically s ealed via the software. A Notified Body can set his password via [W&M notified body seal password]. He can apply the seal by setting [W&M seal]. Here some data logging is filled in and the related password. This requires a W&M module for Engauge. If the primary value of the product temperature is completely valid, then a W&M indication will be set (e.g. visible in HART SmartView). Unsealing: give the [W&M unseal level 1] and [W&M unseal the level 2] commands successively. History can be made visible via [W&M seal history].

7.3.8.4 Commissioning 7.3.8.4.1 Commissioning Parameters for 1 or 2 RTDs (3- and 4-wire) Temperature

Calculations NOTE: Make sure the RTD/MPT jumper is set to RTD.

☛ The following entities must be set by Engauge or HART SmartView for a correct functioning of the FII-RTD module in an instrument. The default values are available after initialization of the non-volatile memory.


till the first RTD floating point number: <-x.x .. +x.x>

<80.0>

[Second element offset] if applicable

The distance from tank zero till the second RTD


<0.0>

[Number of elements] The number of RTDs used <1..2> <0>

[Element type] The type (material) of the used RTDs

<Pt100 large + small> <Ni191> <PtCu100> <Cu100> <Cu90 enraf + beacon + weston/ solartron/nulectrohms> <Sangamo MRT> <Sangamo spot>

<No type>

[Measurement type] Selects RTDs, MPT, or MRT.

<RTD 3wire> <RTD 4wire> <MPT> <MRT>

<No type>

[RTD configuration] Selects how the RTDs are positioned.

<RTD1 in tank> <RTD1 and RTD2 in tank> <RTD1 in tank and RTD2 ambient> <RTD1

bi t>

<No configuration>

COMMISSIONING


7.3.8.4.2 Commissioning Parameters for MPT Temperature Calculations

NOTE: Make sure the RTD/MPT jumper is set to MPT.

☛ The following entities must be set set by Engauge or HART SmartView for a correct functioning of the FII-RTD module in an instrument. The default values are available after initialization of the non-volatile memory.


till the bottom of the probe floating point number: <-x.x .. +x.x>

<80.0>

[Number of elements] The number of elements used

<1..6> <0>



<No type>



<No type>

[MPT sensor length] The length of the MPT probe


<80.0>

COMMISSIONING


7.3.8.4.3 Commissioning Parameters for MRT Temperature Calculations

NOTE: Make sure the RTD/MPT jumper is set to MRT (= MPT position).

☛ The following entities must be set by Engauge or HART SmartView for a correct functioning of the FII-RTD module in an instrument. The default values are available after initialization of the non-volatile memory.


till the bottom of the probe floating point number: <-x.x .. +x.x>

<80.0>

[Number of elements] The number of elements used

<1..6> <0>



<No type>



<No type>

COMMISSIONING


7.3.8.4.4 Commissioning Parameters for All Types of Probes

Engauge *Product temperature* Tab

☛ The following entities can be set set by Engauge or HART SmartView for a specific functioning of the FII-RTD module in an instrument. The default values are available after initialization of the non-volatile memory; so check each entity for its correctness.


product level distance above an element before this element is taken into account in the average product temperature calculation


<0.5>

[Hysteresis] This is a hysteresis mechanism distance around the switching points of the elements that are taken into account in the calculation.


<0.1>

[High high alarm] [High alarm] [Low alarm] [Low low alarm]



<1.0E22>

[Alarm test enable]

Enables (if activated, see next listed entity) the simulation of one of the 4 alarms for a minute, by simulating the actual measured Primary Value is slightly below or above the alarm threshold.

<Enable> <Disable>

<disable>

[Alarm test]


<No Alarm> <High-high alarm> <High alarm> <Low alarm> <Low-low alarm>

<No Alarm>

[Function identification] The current module’s function name. This function is visible on the HART SmartView di l


[Element offset] Each element can individually be given an offset.


<0.0>

COMMISSIONING


Name Explanation Value Range Default [Element weighing factor]

Each element can individually be given a weighing factor, which is applicable if the calculation method is CUSTOM.


<1.0>

[Gauge temperature scale] Determines whether the IPTS-68 or ITS-90 scale is used.

<IPTS-68> <ITS-90>

<ITS-90>

[Low element usage] See Figure 7-24 <No Exclusion> <Static Exclusion> <Dynamic Exclusion>

<No Exclusion>

[Low element behaviour] See Figure 7-24 <Temp To Fail> <Temp To Last Valid> <Temp Use First Element> <Temp Use Second Element>

<Temp To Fail>

[Temperature element exclude zone]

See Figure 7-24 floating point number: <-x.x .. +x.x>

<1.0>

[Smoothing level] See Figure 7-24 floating point numbers: <-x.x .. +x.x>

<0.0>

[MPT element position mode] [Only for MPT]

Determines whether the element positions are automatically calculated (based on sensor length) or manually entered.

<Automatically> <Manually>

<Automatically>

[RTD element positions] [Only for MPT]

If MPT element position mode is MANUALLY then here the positions can be filled in.


<0.0>

[Averaging constant filter] Enables or disables a averaging constant filter.

<enable> <disable>

<enable>

[Averaging constant] Value of how much of the old calculated value is used with respect to the new calculated value

<0.0 .. 1.0> <0.9>

[Temperature range check]

Enables or disables the fact that an element which is outside a temperature range will lead to temperature fail. (See also Figure 7-23 )

<enable> <disable>

<disable>

COMMISSIONING


Name Explanation Value Range Default

[Element skipping] Enables or disables the fact that elements can be skipped if an element is outside a temperature range.

<enable> <disable>

<disable>

[Maximum skipped elements] The number of elements that can be skipped

<1,2> <1>

[Median filter] Enables or disables a median filter of 5 levels deep (spike filtering).

<enable> <disable>

<enable>

[Temperature calculation method] The way the average temperature is calculated (see also features above)

<Standard> <Custom> <Enhanced>

<Enhanced>

[MRT length table] [Only for MRT]

Specifies whether a fixed range of MRT resistors is used (= <F> ) or user configured lenghts (= <T>). Fixed lengths are: 0.65, 1.25, 1.95, 2.85, 4.15, 5.65

1 character

<F> <T>

<F>

[MRT element length used if MRT length table is 'T'] [Only for MRT]

The lengths of the MRTs including anchor eye


<0.0>

Engauge * Vapour temperature * Tab

NOTE: Some settings for Vapour temperature calculations are shared via the product temperature settings.

☛ The following entities can be set by Engauge or HART SmartView for a specific functioning of the FII-RTD module in an instrument. The default values are available after initialization of the non volatile memory; so check each entity for its correctness.

COMMISSIONING


Name Explanation Value Range Default [Gas immersion depth]

The minimum required distance below an element before it is taken into account in the average Vapour temperature calculation


<0.5>


4 Thresholds for activating a related alarm status in the Primary Value


<+1.0E22>

[Alarm test enable] Enables (if activated, see next listed entity) the simulation of one of the 4 alarms for a minute, by simulating the actual measured Primary Value is below or above the alarm threshold.

<enable> <disable>

<disable>

[Alarm test] Activates and selects at the same time the Alarm test (if enabled with the [Alarm test enable] listed before, and the 4 alarm thresholds are properly set).


<No Alarm>

[Function identification] The name of the current function of this module. This name is visible on the HART SmartView.


COMMISSIONING


Engauge * Ambient temperature * Tab

NOTE: Some settings for ambient temperature calculations are shared via the product temperature settings.

☛ The following entities can be set by Engauge or HART SmartView for a specific functioning of the FII-RTD module in an instrument. The default values are available after initialization of the non-volatile memory; so check each entity for its correctness.

Name Explanation Value Range Default [High High alarm] [High Alarm] [Low Alarm] [Low Low alarm]

4 Thresholds for activating a related alarm status in the Primary Value


<+1.0E22>

[Alarm test enable]


<enable> <disable>

<disable>

[Alarm test]



<No Alarm>

[Function identification] The name of the current function of this module. This name is visible on the HART SmartView.

13 characters <Ambient temp.>

7.3.8.4.5 Commissioning Check

☛ After having checked/set all before listed entities, make sure

the [Board Commissioned], the [Product temperature Commissioned], the [Vapour temperature Commissioned], and the [Ambient Temperature Commis- sioned] entities are <True>;

the [Board Health], the [Product temperature Health], the [Vapour temperature Health], and the [Ambient Temperature Health] entities are <GOOD>.

For viewing the software version, the Engauge Generic tab can be viewed; also a Reset board command can be issued here.

NOTE: In the HART SmartView situation, the Commissioning flag must be ‘G’ and the Health flag must be ‘Y’.

COMMISSIONING


HART Analog Outputs (HCI-HAO)


The Host Communication Interface – HART Analog Output (HCI-HAO) is a HART® slave module which communicates with the associated HART master over the HART bus.

Figure 7-25 The HCI-HAO board

The HART protocol is a bi-directional master-slave communication protocol, which is used to communicate between intelligent field instruments and host systems.

The HCI-HAO board has a planar transformer for galvanic isolation from the HART bus. See Figure 7-25.


COMMISSIONING


7.3.9.2 Functional Description

HCI-HAO is a HART slave module, which uses standard HART communication to communicate with HART-devices. This module makes use of the Bell 202 Frequency Shift Keying (FSK) standard to superimpose digital signals at a low level on the 4–20 mA analog signal.

Figure 7-26 The analog and digital signals within the HART® communication The HCI-HAO works as an interface board between FlexConn boards and a HART master, and it makes the data available on the HART bus.

The user needs to set the required linked variable details.

The linked primary variable is mapped between 4–20 mA on the analog output depending on the range values set. The linked variables are scanned every 1 second and so is the analog output refresh rate.

The HCI-HAO is configurable by:

a HART communicator a local HART SmartView Engauge

The HCI-HAO (board ID = 11) has following two functions:

Function Category Type Sub-type 1 - HART communication Communication Instrument slave HART

2 - Analog output Sensor Analog output 4 - 20 mA

COMMISSIONING


All the HART universal commands and some common practice commands are supported by HCI-HAO. These are listed in the below tables.

HART Universal Ccommands Command no. Description

0 Read Unique Identifier1 Read Primary Variable2 Read Loop Current and Percentage of Range 3 Read Dynamic variables and Loop Current 4 Reserved5 Reserved6 Write Polling Address7 Read Loop Configuration8 Read Dynamic Variable Classifications 9 Read Device Variable With Status10 Reserved11 Read Unique Identifier Associated with Tag 12 Read Message13 Read Tag, Descriptor, Date14 Read PV Sensor Information15 Read Device Information16 Read Final Assembly Number17 Write Message18 Write Tag, Descriptor, Date19 Write Final Assembly Number20 Read Long Tag21 Read Unique Identifier Associated With Long Tag 22 Write Long Tag

HART Common Practice Commands Command no. Description

34 Write Primary Variable Damping Value 35 Write Primary Variable Range Values36 Set Primary Variable Upper Range Value 37 Set Primary Variable Lower Range Value 38 Reset Configuration Changed Flags40 Enter / Exit Fixed Current Mode41 Perform Self Test42 Perform Device Reset44 Write Primary Variable Units48 Read Additional Device Status53 Write Device Variable Units72 Squawk

COMMISSIONING


7.3.9.3 Other HCI-HAO features

Planar transformer for galvanic isolation from HART bus.

Malfunctioning of the HCI-HAO card (or any linked cards) is revealed on the HART bus by means of the device status.

If any fatal errors occur during operation - which will run the program into an undesired situation - then a software reset (Warm Reset) is given to the HCI-HAO software. During this situation, the output of the module remains at the desired level till the software starts normal working. Handling of a fatal error is a general FlexConn function. This will update the appropriate entity as well.

Unit conversions for the linked variables are possible. All the linked variables available through linking (data read from other FlexConn boards) are in SI units. Accepted units are listed in the table below.

Sensor Type Accepted HART Units Abbreviation HART Unit Code

Temperature Degrees Celsius °C 32 Degrees Fahrenheit °F 33

Pressure Pounds per square inch psi 6 Pascal Pa 11 Kilo Pascal kPa 12

Level Feet ft 44 Meters m 45 Inches in 47

Density Kilograms per cubic meter kg/m3 92 Pounds per cubic foot lb/ft3 94 Degrees API API 104

Analog output read back mechanism, which is used to indicate any errors in the analog output section. An error can be indicated using the control relay on the FII-DO module over the CAN bus. If some error is found in the DAC read back, then the same is updated in function 2 (sensor) health, as per following details in status and status codes:

Status <BAD>

Status Category <GENERAL_HARDWARE_FAIL>

Status Code <DAC_READ-BACK_FAIL>

Active and Passive mode of operation for Loop current.

COMMISSIONING


Multi-drop mode supported to connect more than one HART- compatible device on HART bus. For operating the device in Multi- Drop mode, user needs to select the polling address to a non-zero value. Making the polling address to a non-zero value makes the output current mode to Fixed_4_20_MA (4 mA fixed). Non-zero polling address will automatically make the output current mode to Fixed_4_20_MA. All the HART-compatible devices connected over the HART bus must have different polling addresses. Multi-drop mode is supported only in Passive mode of loop configuration. When the output current mode is set to Standard_4_20_MA, the polling address of the device must be made zero.

When the device is not in multi-drop mode (STANDARD_4_20_MA mode selected) then the output current follows the changes in linked PV value.

Scanning of each linked available PV, SV, TV and QV on the CAN- bus with frequency of 1 Hz. That means all the available linked variables are scanned every 1 second.

The analog output is refreshed every 1 second, even if there is no change in the scanned variables. So, the watchdog for analog output is automatically implemented. If the output is not refreshed within 45 seconds then a watchdog to analog output is generated and the output is forced to 0 mA.

During startup, the analog output of the HCI-HAO module is kept low (< 0.5 mA). This value will be there till initialization takes place. Once the normal operation starts the output will follow the linked PV depending upon the output mode setting.

Manual overwrite mechanism. This is a standard FlexConn func-tionality. Separate configuration and command entities are defined for this. See 7.3.9.5 - Board Commissioning.

7.3.9.4 Calibration of the HCI-HAO

A calibration provision is given, which is used to accurately map the analog output between 4 -20 mA using the two range values entered for Primary Variable.

Following table lists all entities required for calibration.

Entity Data Type Type [Analog Output at 4 mA] Float non-volatile R/W

[Analog Output at 18 mA] Float non-volatile R/W

[Calibrate at 4 mA] Undefined command

[Calibrate at 18 mA] Undefined command

[Enter Calibration Mode] Undefined command

[Exit Calibration Mode] Undefined command

COMMISSIONING


NOTE: Commands used in the following calibration procedure can be executed either by using the CAN tool, the HART SmartView, or Engauge.

Calibrate the analog output of the HCI-HAO as follows:

☛ Connect loop resistor at connector CN2

☛ Power up HCI-HAO board

☛ Give command [Enter Calibration Mode]

☛Give command [Calibrate Analog Output at 4mA]

☛ Measure actual output current through the loop resistor, using a current meter

☛ Enter this value in the [Analog Output at 4mA] entity

☛ Give command [Calibrate Analog Output at 18mA]

☛ Measure actual output current through the loop resistor, using a current meter

☛ Enter this value in the [Analog Output at 18mA] entity

☛ Give command [Exit Calibration Mode], to exit the calibration mode

These calibration data are used to calculate the analog output current for the Primary Value (PV).

Until calibration has been carried out, the Health status of the PV and the analog output function will be:

Status <BAD>

Status Category <STATUS_CATEGORY_BAD_GENERAL_CALIBRATION_FAIL>

Status Code <CALIBRATION_SET_POINTS_NOT_CALIBRATED>

COMMISSIONING


7.3.9.5 Board Commissioning 7.3.9.5.1 Basic Configurable Entities Overview

Basic configuration entities of the HCI-HAO board, which are configurable by using HART SmartView, are listed in the following table.

Entity HART SmartViewDisplay

Data Type Type Default Function

[PV Link board ID] PV linked Brd ID Unsigned int8 bits

Non-Volatile <0> Board Specific

[PV Link board instance] PV linked Brd IN Unsigned int8 bits

Non-Volatile <0>

[PV Link function instance] PV linked Brd FI Unsigned int8 bits

Non-Volatile <0>

[PV Link Board Sensor Value] PV link Brd SVAL Enumeration Non-Volatile <PV_LINK>

[SV Link board ID] SV linked Brd ID Unsigned int8 bits

Non-Volatile <0>

[SV Link board instance] SV linked Brd IN Unsigned int8 bits

Non-Volatile <0>

[SV Link function instance] SV linked Brd FI Unsigned int8 bits

Non-Volatile <0>

[Polling Address] Polling Address Unsigned int8 bits

Non-Volatile <0> Communication

[HART PV unit code] PV Unit Code Enumeration Non-Volatile <UNKNOWN[Upper Transducer Limit] Upper Tran Limit Float Non-Volatile <0>

[Lower Transducer Limit] Lower Tran Limit Float Non-Volatile <0>

[Transducer Serial Number] Transducer Sr No Unsigned int32 bits

Non-Volatile <123>

[PV Lower range value] Lw Range Value Float Non-Volatile <0> Sensor (Analog Output)

[PV Upper range value] Up Range Value Float Non-Volatile <0>

[Analog Output mode] HART Mode Enumeration<Fixed 4-20mA> <Standard 4-

Non-Volatile <Standard 4- 20mA>

[Burnout Value] Burnout Value Float Non-Volatile <3.6>

[Burnout Behavior] Burnout Behavior Enumeration<BAD> <UNCERTAIN> <BAD +

Non-Volatile <BAD>

[Enter Calibration Mode] Enter Cal Mode Undefined Command

[Cal Value at 4 mA] Cal Value at 4 mA Float Non-Volatile <0>

[Cal Value at 18 mA] Cal Value at 18 Float Non-Volatile <0>

[Calibrate at 4 mA] Calibrate at 4 mA Undefined Command

[Calibrate at 18 mA] Calibrate at 18 mA Undefined Command

[Exit Calibration Mode] Exit Cal Mode Undefined Command

COMMISSIONING


7.3.9.6 Commissioning ☛ The following entities must be set by Engauge or HART

SmartView for a correct functioning of the HCI-HAO module in an instrument.

Name

Explanation Default

ValueFunctionPart

Function

[PV Link board ID] Board ID of Other FlexConn to be linked as PV to HCI- HAO

<0> Board Board Specific

[PV Link board instance] Board Instance of the linked PV board

<0>

[PV Link function instance] Function Instance of the linked PV board

<0>

[PV Link Sensor Value]* Primary or secondary variable of linked card can be assigned to this

<PV_LINK>

[HART PV unit code] Unit code for linked PV <UNIT_CODE_ UNKNOWN>

Function 1 Communication (HART communication) [HART Upper Transducer

Limit] Upper transducer limit for connected sensor of linked PV board

<0>

[HART Lower Transducer Limit]

Lower transducer limit for connected sensor of linked PV board

<0>

[Polling Address] Polling address of the device, which is used for poll-based addressing

<0>

[Transducer Serial Number]

Transducer serial number of connected sensor of linked PV board

<123>

[Upper Range Value] Upper range value for PV. This value is used to calculate the analog output current.

<0> Function 2 Sensor (Analog Output)

[Analog Output at 4mA] Calibration reading when [Calibrate at 4 mA] command is given

<0>

[Analog Output at 18 mA]

Calibration reading when [Calibrate at 18 mA] command is given

<0>

[Lower Range Value] Lower range value for PV. This value is used to calculate the analog output current.

<0>

[Analog Burnout Value] Analog burnout value in case of malfunctioning device

<3.6mA>

*) Default values for entities marked in GREEN in the above table could be considered as proper

COMMISSIONING


values for making the health for respective Function or Board <GOOD>. However, the user is free to choose these values as per the requirement along with the rest of the entities.

All the entities in the above table would be initialized to their default values after [init novram] command is given. All the entities should have their proper values so as to make the respective Function and Board health to <GOOD> status.

The [Analog Output at 4 mA] and [Analog Output at 18 mA] fields should be entered after giving proper calibration commands (for more details, see 7.3.9.4).

☛ The following entities can be set by Engauge or HART SmartView for a correct functioning of the HCI-HAO module in an instrument.

If one needs to assign SV, TV, QV to HCI-HAO then the corresponding unit codes also needs to be set properly so that the value read from other FlexConn board will be proper.

Name

Explanation Default Value Function

Part Function

[SV Link board ID] Board ID of Other FlexConn which is linked as SV to HCI-HAO


[SV Link board instance] Board Instance of the linked SV board

<0>

[SV Link function instance] Function Instance of the linked SV board

<0>

[TV Link board ID] Board ID of Other FlexConn which is linked as TV to HCI-HAO

<0>

[TV Link board instance] Board Instance of the linked TV board

<0>

[TV Link function instance]

Function Instance of the linked TV board

<0>

[QV Link board ID] Board ID of Other FlexConn which is linked as QV to HCI-HAO

<0>

[QV Link board instance]

Board Instance of the linked QV board

<0>

COMMISSIONING


Name Explanation Default Value Function Part

Function

[QV Link function instance]

Function Instance of the linked QV board


[Linked Primary Value] PV / SV value of linked PV board in the set unit code

<0>

[Linked Secondary Value]

PV value of linked SV board in the set unit code

<0>

[Linked Tertiary Value] PV value of linked TV board in the set unit code

<0>

[Linked Quarternary Value]

PV value of linked QV board in the set unit code

<0>

Name

Explanation Default Value Function

Part Function

[HART SV unit code] Unit code for linked SV <UNIT_CODE_ UNKNOWN>

Function 1 Communication (HART communication)

[HART TV unit code] Unit code for linked TV <UNIT_CODE_ UNKNOWN>

[HART QV unit code] Unit code for linked QV <UNIT_CODE_ UNKNOWN>

[Configuration changed Counter]

Increments every time the configuration is changed

<0>

[Device ID] Same as Enraf Serial number. This is a unique number to every board.

[Device Type] Device type registered with the HART Communication Foundation

<127>

[Manufacturer ID Number] Manufacturer ID registered with the HART Communication Foundation

<148>

[Number of Preambles] Number of preambles required for a request from the HART master

<7>

[Number of Response Preambles]

Number of preambles in the HCI-HAO response stream

<7>

[Fixed Current Value] Fixed analog output current set by HART command 40

<0> Function 2 Sensor (Analog Output)

[Loop Current Mode] If HART mode selected is <Standard 4-20mA>, then it is enabled. If HART mode selected is <Fixed 4-20mA>, then it is disabled.

<Enabled>

[Percentage of Range] Percentage of current PV with respect to the limits set

<0>

COMMISSIONING


7.3.9.7 Hardware Configuration 7.3.9.7.1 Jumper Allocation

The following are typical jumper settings done on the HCI-HAO board.

Jumper Number

Position Connection

Details Description Default Position

Default Connections

JP1 ON Short 2 & 3 W&M Entity Protection OFF Short 1 & 2

JP2 ON Short 2 & 3 Password Read Protection OFF Short 1 & 2

JP3 ON Short 2 & 3 Write Protection All Entities OFF Short 1 & 2

JP4 ON Short 2 & 3 Free OFF Short 1 & 2

JP5 ON Short 2 & 3 Free OFF Short 1 & 2

JP6 ON Short 2 & 3 CAN termination 120E resistor OFF Short 1 & 2

JP7 & JP8 A Short 1 & 2 Active mode for Analog Output A Short 1 & 2

JP7 & JP8 P Short 2 & 3 Passive mode for Analog Output

7.3.9.7.2 LED Allocation

LED Number

Function

LE2 HART data Transmit

LE3 HART data Receive

COMMISSIONING


TRL/2 Fieldbus (HCI-TRL)


The FlexLine 954 servo gauge is an inventory and custody transfer level gauge for storage tanks. It is a state of art technology design with highest reliability components and tested for the industrial level performance across global locations. This is designed to fit into existing Emerson gauging system as an attractive replacement with very minimal changes. The replacement of FlexLine 954 gauge with the existing gauge is a very smooth process and can be quickly done. There will be no change in the existing measurement system network as the replacement is designed to replicate the existing gauging system with no changes in terms of measured parameters, number of sensors, number of inputs/outputs, and relays.

Emulation is open interface design concept covering electrical interface, communication protocol interface and utilizing existing power and cabling resources. This interface makes it easy to incorporate reliable, stable, state of the art precision FlexLine gauges in the existing field bus system from other systems like Emerson.

Key benefits of FlexLine 954 gauge with CAN-TRL/2 communication card:

Replaces Rex, Rex with DAU, and Rex with RDU

Directly connects to Enraf® FCU 2160/65/75 or FBM 2180

TRL/2 Field bus compatible

Supports level, temperature, pressure, relay, Analog I/O, HART inputs

Integrates with Taskmaster Win OPI

Supports configuration directly / via Emerson FCU over TRL/2 Field bus through Smart Link

High reliability – Maintenance free

Utilizes the existing power & cabling infra structure

COMMISSIONING


7.3.10.2 System Description

The FlexLine 954 servo gauges act as Rex gauges with the help of CAN- TRL/2 card. The CAN-TRL/2 communication card for FlexLine gauge is added to integrate to the Emerson system. The Rex Gauge and Rosemount Tankmaster (Emerson tank inventory) communicates over TRL/2 network and uses Modbus protocol. When Rex gauge is replaced in field with FlexLine gauge, the Rosemount TankMaster gets the data (for example: product level, temperature) from FlexLine gauge same as Rex gauge.

The FlexLine gauge 954 has the capability to connect directly to Emerson TRL/2 field bus. The Rex or TRL/2 RTG gauges can be replaced with FlexLine gauge with great ease, minimum modifications, and quick turnaround time and quick turnaround time.

The FlexLine gauge communicates with TRL/2 FSK protocol over Modbus RTU and can interface with Enraf® FCU 2160/65/75 or tank hub 2410 or FBM 2180.

The system integrates with Rosemount TankMaster Win OPI and provides level, temperature, and other inputs to the system. Replace the Rex gauge (with or without DAU) with FlexLine gauge and RDU with Smartline display.

The Figure 7-27 shows the Emerson system with Rex gauges, and one of its gauge is replaced by FlexLine 954 gauge.

Figure 7-27 System Architecture - Rex Replaced with 954 SmartServo FlexLine

COMMISSIONING


NOTE: Ensure that the following devices/network/Hosts should be physically protected in a controlled area:

Gauge and the SmartLink devices

Networks in which the Gauge and the SmartLink nodes operate

Hosts that connect to the Gauge and the SmartLink nodes operate

7.3.10.3 Before You Begin Migration

7.3.10.3.1 Device Mapping

Before mapping the device:

Enraf® FCU checklist: Note the FCU unit ID and FCU modbus address. Cross verify the data base about these entries.

Communication overview: Note the field port that FlexLine will replace and its corresponding group port, if Rex is connected to Enraf® FCU. Confirm with saved database.

RTG general information: Note the RTG unit ID and modbus address This is required for configuring TRL/2.

Data Acquisition Unit: Note the unit ID and modbus address (Required for configuring TRL/2).

Operator Software: Verify the data base, the unit ID and Modbus, address of Rex/RTG, Data Acquisition Unit and Enraf®

FCU and the number of field ports to which Rex/RTG is attached and the number of group ports to which the system with Rosemount Tankmaster is attached. Also note whether the other group port is connected or free.

The following table describes the possible combination of cards:

Rex

AI

HART

AO

Relay Temp Possible combinations of cards in

FlexLine Gauge Option 1 2 0 0 1 or 2 6 or 14 Option1: HRT-1 (AI1 & AI2 as HART input), FII-

DO (Relay) and FII-RTD/ HRT-1. (3 cards). Option2: HRT-1 (AI1), HART-2 (AI2), FII-DO (Relay) and FII-RTD/ HRT-3. (4 cards).

SMV card (Display) NOT possible for option 2.

Option 2 1 1 0 1 or 2 6 or 14 Option1: HRT-1(HART, AI as HART & Temp), FII-DO (Relay) - (2 cards) Option2: HRT-1(HART & Temp), HART-2 (AI), FII-DO (Relay) - (3 cards) Option3: HRT-1(HART), HART-2 (AI), FII- DO (Relay) & FII-RTD - (4 cards)


COMMISSIONING


Rex

AI

HART

AO


FlexLine Gauge Option 3 1 1 1 1 6 or 14 Option1: HRT-1(HART, Temp & AI as HART

input), HCI-HAO (AO), FII-DO (Relay) - (3 cards) Option2: HRT-1(HART, & AI as HART input), FII-RTD (Temp), HCI-HAO (AO) & FII-DO (Relay) - (4 cards) Option3: HRT-1(HART & Temp), HRT-2 (AI), HCI-HAO (AO), FII-DO (Relay) - (4 cards)

SMV card (Display) NOT possible for option 2 & 3. FII-RTD not possible for option 3.

Option 4 2 0 1 1 6 or 14 Option1: HRT-1 (AI1 & AI2 as HART inputs and Temp), HCI-HAO (AO), FII-DO (Relay) - (3 cards) Option2: HRT-1 (AI1 & AI2 as HART inputs), HCI-HAO (AO), FII-DO (Relay), FII-RTD (Temp) - (4 cards)

SMV card (Display) NOT possible for option 2. Analog Input NOT possible with this combination

Option 5 1 0 0 1 or 2 6 or 14 Option1: HRT-1 (Temp & AI1 as HART input),FII-DO (Relay) - (2 cards) Option2: HRT-1 (AI1),FII-DO (Relay) FII- RTD (Temp) - (3 cards)

Option 6 0 1 0 1 or 2 6 or 14 Option1: HRT-1 (HART & Temp), FII-DO (Relay) - (2 cards) Option2: HRT-1 (HART), FII-DO (Relay), FII- RTD (Temp) - (3 cards)

Option 7 1 0 1 1 6 or 14 Option1: HRT-1 (Temp & AI1 as HART input),FII-DO (Relay) & HAO (AO) - (3 cards) Option2: HRT-1 (AI1),FII-DO (Relay) FII- RTD (Temp) & HAO (AO) - (4 cards)


Option 8 0 1 1 1 6 or 14 Option1: HRT-1 (Temp & HART input),FII- DO (Relay) & HAO (AO) - (3 cards) Option2: HRT-1 (HART),FII-DO (Relay), FII- RTD (Temp) & HAO (AO) - (4 cards)


COMMISSIONING


Rex

AI

HART

AO


FlexLine Gauge Option 9 1 1 1 0 6 or 14 Option1: HRT-1(HART, Temp & AI as HART

input), HCI-HAO (AO) - (2 cards) Option2: HRT-1(HART, Temp & AI as HART input), HCI-HAO (AO), FII-RTD (Temp) - (3 cards) Option3: HRT-1(AI1), HRT-2(AI2),HCI-HAO (AO), FII-RTD (Temp) - (4 cards)

SMV card (Display) option 3 NOT possible

Option 10 1 0 1 0 6 or 14 Option1: HRT-1 (Temp & AI1 as HART input), HAO (AO) - (2 cards) Option2: HRT-1 (AI1), HAO (AO), FII-RTD (Temp) - (3 cards)

Option 11 0 1 1 0 6 or 14 Option1: HRT-1 (HART & Temp), HAO (AO) - (2 cards) Option1: HRT-1 (HART), HAO (AO) , FII- RTD (Temp) - (3 cards)

7.3.10.3.2 Saving configuration in database

Save the configuration settings in the database to upload the same configuration after inserting TRL/2 card in the gauge.

To save the configuration settings in the database:

1. On the Rosemount TankMaster page, select the device (for which data must to be saved) on the left pane. For Example: Select LT-52

2. Right click the selected device. The page appears as follow:

COMMISSIONING


3. Select Save Database to File.

The Save Database to File-LT-52 (Version 1.E4) dialogue box appears:

4. Browse and specify a folder to save the configuration settings from the database.

5. Click Save to save the configuration settings of the database.

COMMISSIONING


7.3.10.4 Configuration of Gauge Using SmartLink and Engauge 7.3.10.4.1 Configuration of SmartLink with TRL/2 card

The smartlink system requires Engauge service tool for configuration. The Engauge service tool (version 2.2 and higher) is required for SmartLink modules delivered from September 2007 with software versions:

HCM -GPU A1005 (and higher)

FCM-TRL/2

7.3.10.4.2 Configuration of the Smartlink system The Connection between the PC and the Smartlink

Before you can start to configure the SmartLink you have to connect the SmartLink to PC with the service tool Engauge installed. The communication between the PC and the SmartLink takes place by means of a serial connection. The user must select a free serial port on the PC. The chosen port must be set in Engauge, the maximum comport number is COM24. On the SmartLink side the communication takes place by using the Non Isolated RS232 interface on the HCM- GPU module.

Making new site in Engauge

NOTE: Navigate to C:\Users\Public\Documents\Honeywell\ConfigFiles BoardDescriptor" and paste board descriptor files for FCM-TRL/2 and HCI-TRl/2.

COMMISSIONING


HCM - GPU Module

Figure 7-28 HCM-GPU Screen

Open the Engauge tool from the PC where enguage is installed. Right click on HCM-GPU card.Select Commissioning.

To read the current data of this TAB sheet, press the Read button. Instead, you can also select to press the Read All button available when extending the read function by the arrow at the right side of the read button). Then the current data of all TAB sheets are read.

The TAB sheet Status gives information about the health of the HCM- GPU module (Refer to "HCM-GPU Status").

The TAB sheet Generic gives information on the installed software version and from there two commands can be given.

COMMISSIONING


Reset device button: All modules of the SmartLink are reset

Reset board button: Only the HCM-GPU module is reset

Software version: Current installed software version for the HCM-GPU module.

The TAB sheet Board Specific provides host communication information as baud rate and turn around delay time (Refer to Figure "HCM-GPU Board Specific").

Figure 7-29 HCM-GPU Board Specific

Baud rate

Host communication baud rate of the SmartLink. The default setting is

38400. When required, the baud rate can be changed. The following settings are possible:

115200 57600 38400 19200 9600 4800 2400 1200

To make the change effective, press the Send button. When the baud rate is changed, also change the baud rate at the COM port icon (two levels higher).

Turn around delay

COMMISSIONING


This setting is used for host systems that cannot switch directly from sending to receiving. The delay time can be set between 0 and 2000 msec.

On the TAB sheet GPU-slave communication parameters can be set such as: GPU and FlexConn interface addresses, parity and modem control type (Refer to Figure "HCM-GPU Slave").

Figure 7-30 HCM-GPU Slave

Identification:

An 8 character long name for the HCM-GPU board.

GPU interface address:

The address of the SmartLink, ranging from 0 till 9 (similar as the CIU address). Each SmartLink, connected to the same PC ComPort, must have a unique address. If the GPU interface address is changed from default, and the new address has been sent to the HCM-GPU module, then also change the address at the SmartLink icon Properties TAB sheet (one level higher).

COMMISSIONING


FlexConn interface address:

The address for FlexConn communication, ranging from 1900 till 1999. Each SmartLink, connected to the same PC ComPort, must have a unique address. Similar as with the GPU interface address, if changed from default, also alter this FlexConn address at the SmartLink icon (one level higher).

Password:

6 alpha-numerical characters. ChTRanging of some entities requires a password. Default, ENRAF2 (or with newer software versions: AAAAAA) is used as password. Unless it is changed in this entity; then is requested for the password.

Parity:

Can be set to: Odd, Even or None. Standard Enraf GPU protocol (and

FlexConn protocol) uses Odd parity.

Modem control type:

The modern control type Can be:

- Isolated RS232 (uses connector CN2, marked 1 to 4)

- Isolated RS485 (uses connector CN3, marked 5 to 8)

- Non isolated RS232 (uses 9 pin D-type connector)

- Non isolated RS422 (uses 9 pin D-type connector)

- Non isolated RS232 (handshake) (uses 9 pin D-type connector)

When it is changed from default, make sure to adapt the communication line according to the new setting.

ACK mechanism:

Can be set to Enable or Disable. When enabled, the SmartLink transmits ACK characters about every 50 msec. after a host request is received and the reply message is not yet ready.

Function identification:

In the SmartLink, the HCM-GPU module has the function of: GPU-slave (the host is the GPU-master).

COMMISSIONING


7.3.10.4.3 FCM-TRL/2 Module

Figure 7-31 FCM-TRL/2 Screen

Right click on FCM-TRL card. Select Commissioning. The TAB sheet Status gives information about the health of the TRL/2 module master

COMMISSIONING


The TAB sheet Generic gives information on the installed software version, the board instance number and from there three commands can be given (Refer to Figure 7-32 "FCM-TRL/2 Specific").

Figure 7-32 FCM-TRL/2 Specific

Reset device button:All modules of the SmartLink are reset

Reset board button:Only the FCM-TRL/2 module is reset

Test LED’s button:The TxD and RxD led’s are switched on for 10 seconds. The selected FCM-TRL/2 Module is identified. This is useful incase more than one FCM- TRL/2 Module is present.

Board Instance: If more than one FCM-TRL/2 Module is present in the SmartLink, each FCM- TRL/2 Module needs to have a unique board instance number. Range: 0 till 9.

Software version:Current installed software version for the FCM- TRL/2 module.

COMMISSIONING


On the TAB sheet TRL/2 Modbus Master gauges modbus address can be set (Refer to Figure 7-33 "FCM-TRL/2 Modbus Master").

Figure 7-33 FCM-TRL/2 Modbus Master

NOTE: You can enter maximum 20 gauges Modbus address for commissioning at a time. If you want to commission more gauges, delete the first 20 modbus address on the TRL2 Modbus page after commissioning them and add next 20 gauges address and commission them. All the gauges will be listed on the left pane after every commissioning.

Identification:

An 8 character long name for the FCM- TRL/2 board.

GPU instrument start address:

GPU instrument stop address:

When one FCM- TRL/2 Module is used in the SmartLink, the default start and stop addresses (0 and 99) can be used.

When two or three FCM-TRL/2 Modules are used in the SmartLink, a division must be made of the full range; for instance:

l 99 for the second FCM- TRL/2 Module or

0 till 29 for the first FCM- TRL/2 Module

COMMISSIONING


30 till 59 for the second FCM- TRL/2 Module

60 till 99 for the third FCM- TRL/2 Module

FlexConn instrument start address:

FlexConn instrument stop address:

When one FCM- TRL/2 Module is used in the SmartLink, the default start and stop addresses can be used.

When two or three FCM- TRL/2 Modules are used in the SmartLink, a division must be made, like described above.

NOTE: This is only required when FlexConn gauges are connected (like the 954 SmartServo FlexLine).

Time-out GPU instrument reply:

A time-out can be specified on the instrument’s reply record. The timeout can be set between 10 and 2000 msec.

Password:

Refer to the password description of the HCM-GPU module.

Function identification:

In the SmartLink, the FCM- TRL/2 module has the function of: TRL/2- master (the instrument is the TRL/2- slave).

COMMISSIONING


7.3.10.5 Configuration of Gauge TRL/2 through Engauge

You must configure the gauge TRL/2 through engauge. Follow the steps to configure the gauge TRL/2:

1. Connect the HCI TRL/2 card in FlexLine954 gauge.

2. Scan the gauge through SmartLink.

3. In the Engauge tool, right click on HCI-TRL board. Click on Commis- sioning

4. The TAB sheet TRL2 Modbus Slave appears:

5. Under commissioning do the configuration as follows:

a) Enter the Rex Unit ID, DAU Unit ID, Rex Modbus Address, DAU Modbus Address, GPU instrument address, FlexConn instrument address.

NOTE: The basic configuration (Rex Unit ID, DAU Unit ID, Rex Modbus Address, DAU Modbus Address, GPU instrument address, FlexConn instrument address) of Gauge TRL/2 card must be done using Engauge tool through SmartLink..

NOTE: The parameter for Rex Unit ID, DAU Unit ID, Rex Modbus Address, DAU Modbus Address should be entered as per emerson system, as in saved database (Refer "Saving configuration in database").

COMMISSIONING


a) Click Read.

b) Click Send.

6. Click on Status tab.

The page appears as follow:

7. Select True from the Commissioned [TRL/2 Modbus Slave] drop down menu.

8. Click Read.

9. Click Send.

10. Click on Generic tab.


COMMISSIONING


11. Check the Firware version is correct, and if you want to reset board and Novram you can reset using this tab.

12. Open the machine where Engauge tool is installed.

13. Create new site. Refer Installation and Operation Manual Engauge 2.6 - Professional.

14. Add device. Refer Installation and Operation Manual Engauge 2.6 Professional.

15. Add field connector. See Installation and Operation Manual Engauge 2.6 - Professional.

16. Add Tank. See Installation and Operation Manual Engauge 2.6 - Professional.

17. Add gauge. See Installation and Operation Manual Engauge 2.6 - Professional.

18. Scan the field for connected instruments and field connectors (interfaces).

19. Add the GPU and Flexconn address in the Engauge tool.

COMMISSIONING


7.3.10.6 Firmware Upgrade 7.3.10.6.1 General

The Firmware Upgrade can be done for two boards:

1. SmartLink TRL/2 (FCM-TRL)

2. Gauge TRL/2 (HCI-TRL)

7.3.10.6.2 Firmware Upgrade through Engauge

NOTE: The Firmware upgrade process is same for both SmartLink TRL/2 and Gauge TRL/2 boards.

When smartlink based direct upgrade is not possible, upgrade of gauge TRL2 firmware should be done through CAN-SD Card and not through FCU.

Follow the steps to upgrade the firmware:

1. Scan the FlexConn Board.

NOTE: After scanning if communication is proper, the connected devices on CAN drive will be automatically displayed.

2. Select Device and right click for options.

3. Select Firmware upgrade.

The window appears as follow:

COMMISSIONING


4. Click on Browse to select the file.

5. Select .MHX file from the folder and click OK. 6. Click on Start.

The Firmware is upgraded for SmartLink TRL/2.

COMMISSIONING


7.3.10.7 Firmware Upgrade of HCI-TRL/2 or FCM-TRL/2 through CAN-SD Card

Follow the steps to upgrade firmware for HCI-TRL/2 or FCM-TRL/2 through CAN-SD card.

1. Insert the card in a card reader and connect it to PC.

2. Create a folder in the card and name it as “Firmware”.

3. Add/Copy the bin format file to the card inside the Firmware folder.

For Example: 0_A1001.025

4. Remove the card from the PC and insert in CAN-SD (TII-SD) card.

5. Connect the card to the gauge.

6. During Firmare upgrade the following process occurs:

The health LED blinks indicating the health status. After few seconds

Amber light (LED 2) blinks indicating the firmware upgrade process. Once the upgrade starts the card will go to bootloader state.

After upgrade is completed, the card gets back to normal state.

7. The Firmware is upgraded for HCI-TRL/2 or FCM-TRL/2 through CAN- SD card

COMMISSIONING


7.3.10.8 Replacement Scenario

7.3.10.8.1 Replacing Rex Gauge

The Rex gauges are replaced with CAN TRL/2 FlexLine 954 gauges. Follow the steps to replace Rex gauge:

1. Save backup of Rex configuration from Rosemount TankMaster. Refer to Section "Saving configuration in database"

2. Set the device to manual mode. Configure the CAN TRL/2 FlexLine gauge from Engauge. Refer to Section 7.3.10.3.2 "Configuration of Gauge TRL/2 through section Engauge"

3. Replace the Rex gauges with FlexLine gauge.

4. Connect all the transmitters and sensors to flexline and connect flexline gauge in TRL/2 network.

5. Connect Engauge to Enraf® FCU or FBM based on install base. The converter required for connecting Engauge to FBM/FCU.

6. Configure/Calibrate all the measurement cards to match Rex configuration (Offset, threshold, calibration etc) using Engauge.

7. Configure Analog input and HART input entities from Engauge. Example: Functionalities supported by these cards in Rex like Product Pressure, vapour temperature etc.

8. Disconnect Engauge and connect to Rosemount TankMaster (If FBM or if the second group port of FCU connected to DCS).

9. Restore all the saved Rexgauge configuration to FlexLine from Rosemount TankMaster. To restore the saved Rexgauge configuration:

a) On the Rosemount TankMaster page, select the device (for which data must be uploaded) on the left pane.

b) Right click on the selected device.

COMMISSIONING



c) Select Upload Database. The dialogue box appears as follow:

d) Click on Browse. Use the path where you saved the database.

COMMISSIONING


e) Select the file. f) Click on Upload.

The configuration files are uploaded.

10. FlexLine reports data similar to Rex gauge which is replaced

COMMISSIONING


7.3.10.8.2 Possible Configuration Scenarios - FlexLine 954 Gauge

The following schematics represents the possible configuration scenarios for connecting the 954 gauge interfacing to Rosemount TankMaster and Enraf Engauge tool with all possible intermediate devices.

Figure 7-34 Configuration Scenario 1

NOTE: Configuration path: Engauge > SmartLink > Gauge Communication path: TankMaster > FBM > Gauge

COMMISSIONING


Image: t.b.d


NOTE: Configuration path: Engauge > SmartLink > FCU > Gauge Communication path: TankMaster > FCU > Gauge

Image: t.b.d


NOTE: Configuration path: Engauge > SmartLink > FCU > | Gauge Communication path: TankMaster > FBM > FCU > Gauge

COMMISSIONING


Image: t.b.d


NOTE: Configuration path: Engauge > SmartLink > Gauge Communication path: TankMaster > FBM > FCU > Gauge

COMMISSIONING


7.3.10.9 Troubleshooting 7.3.10.9.1 Gauge Scan Issue

1. Scan the SmartLink and check for the gauge address mentioned in FCM-TRL/2 card.

2. If gauge address is not entered, enter the gauge address and GPU address and read all the board parameters.

3. Reset FCM-TRL/2 card after reading all the parameters.

4. Make Commissioned option as “True” and press send.

5. Scan the gauge with proper Flex-conn and GPU address provided in FCM-TRL/2 card (Recheck gauge and GPU of gauge is same as entered in the FCM-TRL/2 card before scanning the gauge).

7.3.10.9.2 TII-XR card Detection Issue

1. Scan the smartlink and provide respective gauge address to the cards before you scan the cards.

2. Check if all cards are scanned which are present in the gauge.

3. If TII-XR card is not detecting, check all other flex conn boards for which the level parameter is linked are blinking with healthy (Blue LED light comes on for every 5 seconds) status (Particularly HCI- HAO card).

4. If any of the Flex-conn board for which level parameter is linked and is not healthy then switch off the gauge and remove the unhealthy flex_conn board from the gauge.

5. Scan the gauge and observe TII-XR card is appeared in scanning.

If the TII-XR card is appeared in scanning:

Re-insert affected Flex_conn board into gauge (Gauge should be switched off).

Restart gauge and scan all boards once again.

If the TII-XR card is not appeared in scanning:

Hardset the gauge and repeat all the steps from step 1.

COMMISSIONING


7.3.10.9.3 HCI-TRL/2 detection issue

1. Reset HCI-TRL/2 card every time after firmware upgrade of TRL/2 card is performed.

2. If HCI-TRL/2 card appears more than one time when gauge scan is performed, reset NOVROM of HCI-TRL/2 gauge then provide all gauge addresses and rescan the gauge.

3. If gauge scan Time out error appears then restart smart link and try to scan again (check gauge address mentioned in FCM-TRL/2).

7.3.10.9.4 Firmware Upgrade of HCI-TRL2 using CAN-SD card

1. Store Binary format firmware of HCI-TRL/2 card in SD card (0_A1000B.026)

2. Switch off the gauge and insert CAN-SD card with suitable firmware inside gauge.

3. Switch on the gauge observe LED pattern of SD card and HCI-TRL/2 card.

4. Remove SD card from CAN rail or from gauge after firmware upgrade completed.

NOTE: If CAN-SD card remains inside the gauge after firmware upgrade, it will upgrade firmware whenever gauge is restarted for some other purpose and may lead to miscellaneous causes.

7.3.10.9.5 Firmware Upgrade issue/Gauge scan issue when smart link connected to FCU host port

1. Check Time out, Retries options in Engauge. if Timeout is less than 8000ms then Firmware upgrade will fail when it’s done via FCU.

2. Keep Time out as 8000ms and set Retries as 3 in Engauge COM setting option.

3. Scan gauge and Upgrade Firmware of any Flex_conn boards.

7.3.10.9.6 Smart link scan issue

1. Scan smart link if it shows network connection error.

2. Open “services” option in Engauge PC.

3. Select Honeywell Engauge Data service option, Right click and select Restart.

4. Scan Smart link from Engauge Tool.

COMMISSIONING


7.3.10.9.7 Gauge scan after Novram reset

1. Do Novram reset of HCI-TRL card.

2. Scan the gauge. The error message appears giving information about gauge scan fail.

3. Click on FCM-TRL card in smartlink and set GPU and Flexconn address of particular gauge as “0”.

5. Scan the gauge again.

Integrated display (TII-LCD) 7.3.11.1 Introduction

The integrated display board (TII-LCD) is a module that communicates to the TII-SRV to read Level process value, and to the FCI-HRT/TII-RTD to read temperature process value. The values are displayed on the integrated LCD display.

COMMISSIONING


COMMISSIONING


7.3.11.2 Commissioning of TII-LCD

For correct functioning of the TII-LCD module in the instrument, the following entities can be set by using either Engauge or HART SmartView.


[Level type] <Innage>

<Ullage>

<Innage> It determines level value to be displayed on the LCD is Innage Type or Ullage Type

[Display contrast] <0…63> 2 digits <35> Used to set the contrast of the LCD

[Identification] 8 characters

E.g. Tank_123

<--------> Name of the tank or instrument. This tank name will be displayed during start up and showing of initial screen is enabled. Only special character allowed is “_”

[Temperature Units] <Celsius>

<Fahrenheit>

<Celsius> Temperature value is converted based on the Temperature unit selected and displayed on the LCD

[Zero format] <format Numerical 0>

<format letter O>

<format Numerical 0>

Zero of Process value Level and Temperature is displayed as per this configuration

[Level units] <Metres>

<Feet>

<Inches>

<Fraction>

<Metres> Based on the level unit selected process value read from servo is converted and displayed on the LCD

[Decimal Separator] <Point>

<Comma>

<Point> Based on this configuration decimal separator is displayed on the LCD screen

[Tenth millimeter selection]

<enable>

<disable>

<enable> Determines whether the tenth millimeter is shown on the display in the [PV screen] in case a level entity is shown.

COMMISSIONING



[LCD switch off time] <1 ..255> 3 digits <15> This is used to switch off the LCD to increase the life time of LCD. LCD will be switched of once time is elapsed from the time of start-up. Unit is minutes(Min) for this entity

Note: Configuring LCD switch off time as zero will keep the LCD on always

[Backlight brightness]

<0..100> 3 digits <75> Used to control the brightness of the backlight.

[Show initial screen] <enable>

<disable>

<disable> With this entity the “Initial screen” appearance can be configured.

[Status Ambient light sensor]

<enable>

<disable>

<disable> This is read only entity to display the Ambient Light Sensor status

[Pixel test] - - This is command entity to test the LCD. When this command is issued, it will set all pixel ON for two seconds and OFF for two seconds, then switches to normal process screen

[Display Format] <Display format Level Temperature>

<Display format test>

<Display format Level Temperature>

Used to select between default display screen of Level and Temperature value and Test Display screen of only the Level Value

COMMISSIONING



[LCD text] 60 Characters - This field is used to display any maintenance string on the display. String entered in the entity will appear on the display if Start presenting Text command is issued. It will switch back to default Level and Temperature screen if Stop presenting Text command is issued

[Start presenting text]

- - This is command entity to issue command to display LCD text on the Display

[Stop presenting text]

- - This is command entity to issue command to Stop presenting text on the display and switch to default display screen

[Display record] - - Display record entity is used to display the data appearing on the display

[Board W&M intended]

<enable>

<disable>

<disable> Based on this configuration, LCD module checks the status of W&M read from servo and update the LCD with right symbol.

[Ambient Light Sensor threshold]

<0…3000> 4 digits 500 Ambient Light Sensor Threshod value is used as reference value to switch on LCD if LCD is switched off after configured switch off time. Switch on LCD is achieved by covering of Ambient Light Sensor with hand or by using Flash light on the the Ambient Light sensor. If appropriate Ambient Light Sensor threshold value is not used LCD may not be switched on. In that case configuring LCD switch off time to zero will switch on the LCD.

COMMISSIONING


7.3.11.2.1 Commissioning screens of Engauge

TII-LCD -> Commissioning -> Display tab option can be used to perform the required configuration required for correct functioning of LCD.

COMMISSIONING


COMMISSIONING


7.3.11.3 LCD Display screens

TII-LCD consists of the following three screens

1. TII-LCD Start up Screen

2. TII-LCD Initial Screen

3. TII-LCD Level and Temperature Display screen

7.3.11.3.1 TII-LCD Start up Screen

When the device is switched on, the LCD will display the Honeywell Logo of “Honeywell Enraf”. The first screen will perform a pixel test line by line.

7.3.11.3.2 Start up Screen

7.3.11.3.3 TII-LCD Initial Screen

The Initial screen consists of the following content. Displaying of the initial screen is enabled if the Entity “Show initial screen” is configured as “Enable”. Otherwise the LCD screen switches to the “Level and Temperature” display screen after the “start up” screen.

1. Header as 954

2. Firmware version present in the TII-LCD board

3. Checksum of Firmware

4. Tank Identification Name

Initial Screen

Initial screen will be displayed only if Show initial screen: entity is configured as “Enable”

COMMISSIONING


The correct tank name should be entered in the identification entity to display the tank name in the initial screen. Otherwise, it will display underscore characters in the place of the Tank name. The special character allowed in the Tank name is “_”.

7.3.11.3.4 TII-LCD Level and Temperature Display Screen

This section describes the format of Level and Temperature screen and various screens based on the configuration of entities.

LLLLLLLLL ll

aasdoo ###

TTTTTTT tt

Level Unit as per Configuration

Level Value

Level Type as per Configuration

Temperature Value

Temperature Unit/Status

Operational Status

Displacer Status

Motor Limit switch Status

Alarm Status

Refresh Indicator

COMMISSIONING


Level Screens with different unit configured

The below table shows various screens when a different unit is configured using Engauge or HART SmartView.

Level Units Screen

Meter

Inches

Feet

Fraction

Level Screen with different Alarms

The below table shows how different alarms will be reported by the LCD when it reads the alarms from the servo board.

Alarm Screen

High Alarm

High High Alarm

Low Alarm

Low Low Alarm

COMMISSIONING


Level Screen with Limit Switch Status

The below table shows how the limit switch status is display on the LCD when Limit switch is reached in the servo.

Motor Limit Switch Screen

Reached

Not Reached

Level Screen with different displacer status

The below table shows how the displacer movement is presented on the LCD.

Displacer Screen

Down

Up

No movement

SAT Active

COMMISSIONING


Level Screen with different Operational status

The below table shows how the different operational status reads from servo and is displayed on the LCD.

Operational Status Screen

No Status

General CAN-SERVO board Fail

Balance Test

Block

Calibrate

Freeze

Go Down

Go Up

Interface Profile

COMMISSIONING



Lock Test

Measure Frequency

Test Gauge

Tank Profile

Interface 1 Mode

Interface 2 Mode

Interface 3 Mode

Dip Mode

Water Density Dip

COMMISSIONING



Density Water Dip

Test

Lock Test To Level

Lock To Level

Check Bearings

Process value killed

Manual Process Value

COMMISSIONING


Level Screen with different Level Type

The below table shows how the level screens appear when different Level type is configured using Engauge or HART SmartView.

Level Type Screen

Innage

Ullage

Level Screen with Tenth Millimeter selection as Disable

The below screen shows how the level value will appear when the Tenth Millimeter Selection units entity is configured as “Enable/Disable” using Engauge or HART SmartView.

Tenth Millimeter selection

Screen

Enable

Disable

COMMISSIONING


Level Value with health status

The below screen shows how the level value will appear for the different health status of level value.

Health status Screen

GOOD

BAD

UNCERTAIN

No Servo Board

COMMISSIONING


Level Value with Board W&M intended

The below screen shows how the level value will appear with Level unit and Level type when different options on the Board W&M intended are configured.

Board W&M

intended

Board health PV Health W&M Status of Servo

Screen

ENABLE GOOD GOOD TRUE

ENABLE BAD/UNCERTAIN GOOD/ BAD/ UNCERTAIN

TRUE

ENABLE GOOD BAD/

UNCERTAIN

TRUE

DISABLE GOOD GOOD FALSE

DISABLE BAD/UNCERTAIN GOOD TRUE/FALSE

DISABLE BAD/UNCERTAIN BAD/

UNCERTAIN

TRUE/FALSE

COMMISSIONING


Level and Temperature value screen with different contrast value

The below screen shows how the level and temperature value screens will appear when different display contrast values are configured.

Display contrast Screen

35 (default)

45

63

30

20

COMMISSIONING


Level and Temperature Value screen with different Backlight brightness

The below screen shows how the level and temperature screens will appear when different backlight brightness values are configured.

Backlight brightness

Screen

75(default)

100

25

5

Level and Temperature Value with Decimal Separator

The below screen shows how the level and temperature value screens will appear with different decimal separator.

Decimal Separator Screen

Point

Comma

COMMISSIONING


Level and Temperature Value with Zero Format

The below screen shows how the level and temperature value screens will appear with different zero format.

Zero Format Screen

format numerical 0

Format letter O

Level and Temperature Value with different display format

The below screen shows how the level and temperature value screens will appear with different zero format.

Display Format Screen

DISPLAY_FORMAT_LEVEL_TEMPERATURE

DISPLAY_FORMAT_TEST

COMMISSIONING


7.3.11.3.5 LCD text

This entity is used to enter string of 60 character to display it as maintenance message on the display. To display the string entered in the LCD text entity “Start presenting text” command should be used. To return back to default display screen “Stop presenting text” command should be issued.

Note : Special characters are not accepted

Display Record

This entity displays what is appearing on the display. Data appearing on this entity and display should match.

It displays in the format of <Level Value> <Level unit> <Level Type> <Temperature Value> <Temperature Unit> <Level Alarm> <Limit Switch Status><Displacer Status> <Operational Status>

Temperature Value with different Units

The below screen shows how the temperature value will appear with different temperature units

Temperature Unit Screen

Celcius

Fahrenheit

COMMISSIONING


Temperature Value with different Health Status

The below screen shows how the temperature value will appear with different health status.

Health Status Screen

GOOD ACTUAL

GOOD MANUAL

BAD

UNCERTAIN

No Temperature Board

COMMISSIONING


7.3.11.3.6 Ambient Light Sensor

TII-LCD is equipped with an Ambient Light Sensor which helps to increase the life-time of the LCD display. The LCD is switched off after LCD switch off time is expired. So, to activate the LCD again, cover the Ambient Light Sensor by hand during day time and flash light on the Ambient Light Sensor during night time.

Configure Ambient Light Sensor threshold with appropriate value to switch on LCD when covering with hand or using flash light on the Ambient light sensor. Ambient Light Sensor threshold value is used as reference to switch on LCD. When covering the sensor with hand or using flash light on the sensor, if Ambient light sensor channel value does not exceed configured sensor threshold it will not switch on LCD. So, recommended to configure Ambient Light Sensor threshold with appropriate value.

Figure 7-38: Ambient Light Sensor

7.3.11.3.7 LED Allocation

LED Number Function

LED0 It indicates the health of the board. If it blinks every two seconds, once, then health of the board is GOOD

LED1 This blinks for 5 seconds when Ambient Light Sensor is activated

LED2 It blinks based on the process value refresh rate. In normal temperature of zero or greater than zero, process value refresh rate is one second. So, it blinks once for one second, in this scenario.

Ambient Light Sensor

COMMISSIONING


Figure 7-39: Picture of 3 LEDs

7.3.11.4 Error Handling

Errors Possible Reason Resolution LCD not displaying data 1.LCD is not connected properly to

CAN-LCD board 2.Contrast value is set to Low value (less than 20)

1) Perform Pixel test by issuing command from Engauge to check LCD is switching on all pixels for 2 seconds and switching off for 2 seconds respectively. Even after Pixel test also, LCD is not displaying any data, contact service engineer

2) Entering LCD Switch off

time as zero will switch on the LCD and start displaying data. Even after configuing LCD switch off time as zero, LCD is not displaying data, contact service engineer

LCD displaying INVALID data

1.Board health is not GOOD 2.PV status is not GOOD 3.CAN communication fails

Check Board Error using Engauge and take appropriate action.

LCD not displaying after when covering Ambient Light Sensor with hand or flash on the Ambient Light Sensor (at least for 5 seconds)

1. Ambient Light Sensor Failed 2. Ambient Light Sensor threshold is not configured with appropriate

Check Ambient Light Sensor activation indicator LED blinks for 5 seconds continuously when covering it with Hand or Flashing light on it. If it is not blinking for 5 seconds, contact service engineer.

Data refresh indicator LED

Light Sensor Activation Indicator LED Board Health Indicator LED

COMMISSIONING


SIL overfill and underfill protection (FII-SIL)


Field Interface Instrument - Safety Integrity Level (FII-SIL) is an optional FlexConn board. The FII-SIL module provides overfill and underfill protection functionality certified and suitable for use in Safety Instrumented Systems at SIL 2 with systematic capability at SIL 3. It is used with the 954 SmartServo FlexLine tank gauge system.

FII-SIL provides two relay contacts for signaling a safety shutdown or safe state, and one 4-20 mA analog output both for monitoring the product level and signaling a safe state. The presence of two relay contacts provides configuration flexibility, such as separate signaling of overfill and underfill conditions, or the capability of an overfill early warning to allow corrective action before an overfill condition prompts a safety shutdown.

The physical contacts of each relay are closed or energized during normal operation. When a relay is in a safe state, the physical contacts are open or de-energized. This allows loss of power to also signal a safe state.

In compliance with NAMUR NE 43, the analog output signals a safe state when the current at or above 21 mA, or is at or below 3.6 mA.

COMMISSIONING


The following safety categories are monitored continuously to determine whether a safe state should be activated, in the order listed, at a rate of at least once per second.

Monitored Safety Categories

Contact and analog output physical health

Physical module health

Contact and analog output functional health

Product level health

Product level overfill or underfill

Errors 7.3.13.1 Safety Function Status

The Safety Function Status define possible reasons for activation of the safe state for each output. Each is a condition monitored as part of the safety categories outlined in section 7.3.12.1, above.

When the condition causing activation is no longer present, the output may be configured to remain in the safe state (latched) until power is cycled or a reset is initiated. This latching behavior can be enabled or disabled for each of the possible reasons for activation.

The safe state of the analog output can be configured to be a high or low burnout current level. High or low burnout action can also be assigned for each of the possible reasons for activation of a safe state.

Board and function failures are hardware failures which are considered to impact the integrity of the analog output current level. To assure a safe state will always be signalled, these failures always result in a latched burnout current level of 0 mA.

The safety function status error codes, user actions, and the default latching behaviour and burnout action for each are defined below:

COMMISSIONING


Safety Function Status Code User Action Latching Default

Burnout Default

PRODUCT LEVEL DATA CORRUPTEDThe product level value received from the tank gauge is corrupted.

Service the CAN-SERVO board

Disabled High

PRODUCT LEVEL DATA TOO OLD The product level value received from the tank gauge is more than 5 seconds old.


Disabled High

PRODUCT LEVEL DATA FROM WRONG SOURCE The product level value was received from a source that is not a 954 SmartServo tank gauge.

Remove the incompatible board

Disabled High

PRODUCT LEVEL NOT GOOD The product level value received from the tank gauge has a bad status.


Disabled High

PRODUCT LEVEL SCAN TIMEOUT No product level value has been received for more than 5 seconds.


Disabled High

DISPLACER NOT ON PRODUCT LEVEL The Servo tank gauge displacer is not positioned on the product level.

Deploy displacer to measure product level

Disabled High

PRODUCT LEVEL OVERFILL The product level value is above the threshold value.

Correct the product level

Disabled High

PRODUCT LEVEL UNDERFILL The product level value is below the threshold value.

Correct the product level

Disabled High

FIXED FREQUENCY ABOVE SETPOINT The Servo tank gauge displacer is at the high motor limit.

Calibrate the servo level measurement

Disabled High

FIXED FREQUENCY BELOW SETPOINT The Servo tank gauge displacer is at the low motor limit.

Calibrate the servo level measurement

Disabled High

BOARD TEMPERATURE FAILURE The temperature of the FII-SIL module is excessive.

Replace the CAN-SIL board

Disabled High

COMMISSIONING


Safety Function Status Code User Action Latching Default

Burnout Default

DATA MEMORY FAILURE A failure of the FII-SIL data memory has occurred.


Enabled High

CODE CHECKSUM FAILURE The FII-SIL module code memory has become corrupted.


Enabled High

OUTPUT READBACK FAILURE The contact state or analog output level cannot be verified.


Enabled High

BOARD FAILURE A failure of the FII-SIL module electronics has occurred.


Enabled High

FUNCTION FAILURE A failure of the FII-SIL module software has occurred.


Disabled High

COMMISSIONING


7.3.13.2 Safety Shutdown Reason Codes

The Safety Function Status Codes listed below have detail error information in the output’s Safety Shutdown Reason entity.

Safety Function Status Code

Safety Shutdown Reason Codes

BOARD FAILURE

VOLTAGE MON ADC ERROR Communication with the FII-SIL voltage monitor failed

VOLTAGE MON POWER SUPPLY LO LIM_EXCEEDED The power supply voltage is below the lower limit.

VOLTAGE MON POWER SUPPLY HI_LIM_EXCEEDED The power supply voltage is above the upper limit.

VOLTAGE MON LOGIC LO LIM EXCEEDED The internal voltage VDD1 is below the lower limit.

VOLTAGE MON LOGIC HI LIM EXCEEDED The internal voltage VDD1 is above the upper limit.

VOLTAGE MON CAN TRANSMITTER LO LIM EXCEEDED The internal voltage VDD3 is below the lower limit.

VOLTAGE MON CAN TRANSMITTER HI LIM EXCEEDED The internal voltage VDD3 is above the upper limit.

HARDWARE VERSION VOLTAGE OUT OF RANGE The FII-SIL hardware version is invalid

FUNCTION FAILURE

SIL OUTPUT SELF-TEST FAILURE The output function health diagnostics have failed.

CODE CHECKSUM FAILURE

ROM ERROR The FII-SIL firmware is corrupted.

BOARD TEMPERATURE FAILURE

TEMPERATURE MON LO LIM EXCEEDED The FII-SIL module temperature is below the lower limit

TEMPERATURE MON HI LIM EXCEEDED The FII-SIL module temperature is above the upper limit

TEMPSENS SPI COMMUNICATION ERROR Communication with the FII-SIL module temperature sensor failed.

COMMISSIONING




DATA MEMORY FAILURE

NOVRAM ENTITY BCC ERROR The data read from non-volatile memory is corrupted. NOVRAM READ BACK ERROR The data written to non-volatile memory did not read back correctly. NOVRAM CORRUPT The non-volatile memory is corrupted. NOVRAM ADMINISTRATION BCC ERROR The data facilitating access to non-volatile memory is corrupted.

7.3.13.3 Other Errors

There are also other Safety Function Status codes can also cause the outputs to go to a safe state. These errors are not latchable and the AO current is fixed.



Safety Function Not Used

This Safety Function selection is available on all three outputs. When selected, the output is not functional. For the analog output, the output current becomes fixed at 21 mA.

Analog Output Mode Disabled

The analog output is not functional, and the output current is fixed at 0 mA.

7.3.13.4 Uncertain Conditions

These are not errors but are considered to be uncertain conditions, since the requested current level cannot be produced.



Analog Output Over Range

An analog output current level above 20.5 mA is being requested. The actual current level stays at the upper limit of 20.5 mA and the SIL function health status becomes Uncertain.

Analog Output Under Range

An analog output current level below 3.8 mA is requested. The actual current level stays at the lower limit of 3.8 mA and the SIL function health status becomes Uncertain.

Analog Output Zero Span

The Upper Range Value and Lower Range Value are equal, preventing a product level percent of range from being calculated. The output current stays at the upper limit of 20.5 mA and the SIL function health status becomes Uncertain.

Analog Output Not Calibrated

The analog output has not been calibrated. The output current which corresponds to the product level may not be accurate.

COMMISSIONING


Commissioning The FII-SIL module does not require the configuration of any entities for commissioning. By default, the board and all three output functions are already in the commissioned state. However, all outputs are in safe state, so configuration is necessary for the FII-SIL module to be useful.

Proof Testing The FII-SIL module requires periodic user operations to maintain its SIL certification, which are described in the Safety Manual. One of these activities is to perform proof tests on each of the outputs to assure the safe state functionality will perform properly when necessary. A proof test activates the safe state on each of the contacts and analog output by simulating an overfill or underfill condition and exercising the detection logic. A maximum interval can be configured for each output to warn the user if the time from the last proof test (or from the factory default state) has exceeded the interval time. A configurable timeout assures that proof tests will not remain active.

Entities The following entities are mostly specific to the FII-SIL module and are readable or configurable using the Engauge and SmartView tools.

Contact 1 Health, Contact 2 Health and Analog Output Health are generic function entities but use the status codes specific to FII-SIL, as defined in section 7.3.13.1, above.

COMMISSIONING


(RO) = read only

Contact 1

Name Value Range Default Value Description

[Contact 1 Health]

(RO)

Status GOOD UNCERTAIN BAD

Status Category GOOD, ACTUAL VALUE GOOD, STORED VALUE UNCERTAIN, INSTRUMENT BAD, HARDWARE FAILURE BAD, OPERATIONAL FAILURE

Status Code See section 7.3.13.1 “Safety Function Status” for definitions.

Functional health of contact 1. Any status other than GOOD will result in a safe state activation for contact 1.

[Contact 1 safety function]

< Not Used >

< Overfill >

< Underfill >

< Overfill > The condition of product level relative to the threshold which will determine the activation of a contact 1 safe state, as an underfill or overfill condition.

Overfill: activation occurs when the product level is above the Overfill Threshold.

Underfill: activation occurs when the product level is below the Underfill Threshold.

Not Used: contact 1 is activated in a constant safe state and does not perform any function.

[Contact 1 threshold]

< 0 – 3.402823 × 1038 >

(meters)

< 0 > The product level limit value for determining an overfill or underfill condition for contact 1.

COMMISSIONING



[Contact 1 hysteresis]

< 0 – 3.402823 × 1038 >

(meters)

< 0.010 > A value relative to the threshold that will determine the point at which deactivation of a contact 1 safe state occurs after activation by an overfill or underfill condition.

For an underfill, deactivation occurs when the product level is above (threshold + hysteresis).

For an overfill, deactivation occurs when the product level is below (threshold – hysteresis).

[Contact 1 safety function status]

(RO)

Status:

< H >, < O >, < U >, < W >

Status Code:

Defined in Section 7.3.13.1

Status:

< H >

Status Code:

NO ERROR

H: Healthy

O: Overfill condition

U: Underfill condition

W: Warning condition, safe state is active, or proof test is overdue (status code is NO ERROR)

[Contact 1 safety shutdown counter]

(RO)

< 0 – 3.402823 × 1038 >

< 0 > The number of contact 1 safe state activations that have occurred since commissioning.

[Contact 1 safety shutdown reason]

(RO)


NO ERROR The safety function status code identifies the reason for the last time a contact 1 safe state activation occurred.

[Contact 1 switch count]

(RO)

< 0 – 3.402823 × 1038 >

< 0 > The number of contact 1 closures, or transitions from safe state to normal state, since commissioning.

[Contact 1 Start proof test]

Command Initiates a contact 1 proof test if an actual contact 1 safe state is not currently active. Upon activation, contact 1 will open to simulate a safe state. An active poof test will terminate if an actual contact 1 safe state is activated, or if the contact 1 proof test timeout value is exceeded.

COMMISSIONING



[Contact 1 Stop proof test]

Command Terminates an active contact 1 proof test. Upon termination, the normal process will resume and contact 1 will close.

[Contact 1 proof test interval]

< 1 – 3650 >

(days)

< 1825 > The maximum time interval permitted between contact 1 proof tests. If exceed and when a contact 1 safe state is not active, the contact 1 safety function status will change to W to signal a warning that a proof test is overdue. The status code will remain as NO ERROR.

[Contact 1 proof test timeout]

< Auto timeout off >

< 5 minutes >

< 10 minutes >

< 20 minutes >

< 30 minutes >

< 5 minutes > If not < Auto timeout off >, the maximum time duration a contact 1 proof test will remain active. If exceeded the proof test will automatically stop.

[Contact 1 proof test elapsed time]

(RO)

< 0 – 4,294,967,295 >

(days)

< 0 > The elapsed time since the last contact 1 proof test or since commissioning if no contact 2 output proof test has been executed.

COMMISSIONING


Contact 2

Name Permitted Values Default Value Description

[Contact 2 health]

(RO)


Status Category GOOD, ACTUAL VALUE GOOD, STORED VALUE UNCERTAIN, INSTRUMENT BAD, HARDWARE FAILURE BAD, OPERATIONAL FAILURE


Functional health of contact 2. Any status other than GOOD will result in a safe state activation for contact 2.

[Contact 2 safety function]

< Not Used >

< Underfill >

< Overfill >

< Overfill > The condition of product level relative to the threshold which will determine the activation of a contact 2 safe state, as an underfill or overfill condition.



Not Used: contact 2 is activated in a constant safe state and does not perform any function.

[Contact 2 threshold]

< 0 – 3.402823 × 1038 >

(meters)

< 0 > The product level limit value for determining an overfill or underfill condition for contact 2.

COMMISSIONING



[Contact 2 hysteresis]

< 0 – 3.402823 × 1038 >

(meters)

< 0.010 > A value relative to the threshold that will determine the point at which deactivation of a contact 2 safe state occurs after activation by an overfill or underfill condition.

For an underfill, deactivation occurs when the product level is above (threshold + hysteresis).

For an overfill, deactivation occurs when the product level is below (threshold – hysteresis).

[Contact 2 safety function status]

(RO)

Status:

< H >, < O >, < U >, < W >

Status Code:


Status:

< H >

Status Code:

NO ERROR

H: Healthy



W: Warning condition, safe state is active or proof test is overdue

[Contact 2 safety shutdown counter]

(RO)

< 0 – 3.402823 × 1038 >

< 0 > The number of contact 2 safe state activations that have occurred since commissioning.

[Contact 2 safety shutdown reason]

(RO)

Safety Function Status Code NO ERROR The safety function status code identifying the reason for the last time a contact 2 safe state activation occurred.

COMMISSIONING



[Contact 2 switch count]

(RO)

< 0 – 3.402823 × 1038 > < 0 > The total number of contact 2 closures, or transitions from safe state to normal state.

[Contact 2 start proof test]

Command Initiates a contact 2 proof test if an actual contact 2 safe state is not currently active. Upon activation, contact 2 will open to simulate a safe state. An active poof test will terminate if an actual contact 2 safe state is activated, or if the contact 2 proof test timeout value is exceeded.

[Contact 2 stop proof test]

Command Terminates an active contact 2 proof test. Upon termination, the normal process will resume and contact 2 will close.

[Contact 2 proof test interval]

< 1 – 3650 >

(days)

< 1825 > The maximum time interval permitted between contact 2 proof tests. If exceed and when a contact 2 safe state is not active, the contact 2 safety function status will change to W to signal a warning that a proof test is overdue. The status code will remain as NO ERROR.

[Contact 2 proof test elapsed time]

(RO)

< 0 – 4,294,967,295 >

(days)

< 0 > The elapsed time since the last contact 2 proof test or since commissioning if no contact 2 output proof test has been executed.

[Contact 2 proof test timeout]


< 5 minutes >

< 10 minutes >

< 20 minutes >

< 30 minutes >

< 5 minutes >

If not < Auto timeout off >, the maximum time duration a contact 2 proof test will remain active. If exceeded the proof test will automatically stop.

COMMISSIONING


Analog Output

Name Permitted Values Default Value Description

[Analog output health]

(RO)


Status Category GOOD, ACTUAL VALUE GOOD, STORED VALUE UNCERTAIN, INSTRUMENTBAD, HARDWARE FAILUREBAD, OPERATIONAL FAILURE


Functional health of the analog output. Any status other than GOOD will result in a safe state activation for the analog output.

[Analog output mode]

< Disabled >

< Enabled >

< Disabled >

Disabled: the analog output does not function and remains at 0 mA current value.

4-20 mA: The analog output is in normal 4-20 mA mode.

COMMISSIONING



[Analog output safety function]

< Not used >

< Overfill >

< Underfill >

< Overfill and underfill >

< Overfill and underfill >

The condition of product level relative to the threshold which will determine the activation of an analog output safe state, as an underfill or overfill condition.



Overfill and underfill: activation occurs when the product level is above the Overfill Threshold or below the Underfill Threshold.

Not used: the analog output remains in high burnout safe state of 21 mA and does not perform any function.

[Analog output overfill threshold]

< 0 – 3.402823 × 1038 >

(meters)

< 0 > The product level limit value for determining an overfill condition for the analog output.

[Analog output underfill threshold]

< 0 – 3.402823 × 1038 >

(meters)

< 0 > The product level limit value for determining an underfill condition for the analog output.

COMMISSIONING



[Analog output hysteresis]

< 0 – 3.402823 × 1038 >

(meters)

< 0.010 > A value relative to the threshold that will determine the point at which deactivation of an analog output safe state occurs after activation by an overfill or underfill condition.

For an underfill condition, deactivation occurs when the product level is above (threshold + hysteresis).

For an overfill condition, deactivation occurs when the product level is below (threshold – hysteresis).

[Analog output burnout action

< High >, < Low > < High > The burnout action or safe state of the analog output for each of the possible reasons for activating a safe state.

[Analog output high burnout value]

< 21 – 25 >

(mA)

< 21 The safe state current level of the analog output for a condition configured for high burnout.

[Analog output low burnout value]

< 0.5 – 3.6 >

(mA)

< 3.6 > The safe state current level of the analog output for a condition configured for low burnout.

[Analog output upper range value]

< 0 – 3.402823 × 1038 >

(meters)

< 0 > Product level value corresponding to a 20 mA or 100% current level.

[Analog output lower range value]

< 0 – 3.402823 × 1038 >

(meters)

< 0 > Product level value corresponding to a 4 mA or 0% current level.

COMMISSIONING



[Analog output safety function status]

(RO)

Status:

< H >, < O >, < U >, < W >

Status Code:


Status:

< H >

Status Code:

NO ERROR

H: Healthy



W: Warning condition, safe state is active, or proof test is overdue (status is NO ERROR).

[Analog output safety shutdown counter]

(RO)

< 0 – 3.402823 × 1038 > < 0 > The number of safe state activations that have occurred for the analog output.

[Analog output safety shutdown reason]

(RO)


NO ERROR The safety function status code identifying the reason for the last time an analog output safe state activation occurred.

[Analog output start overfill proof test]

Command Initiates an analog output overfill proof test if an actual analog output safe state is not currently active. Upon activation, a simulated overfill condition will occur. An active poof test will terminate if an actual analog output safe state is activated, or if the analog output proof test timeout value is exceeded.

[Analog output start underfill proof test]

Command Initiates an analog output underfill proof test if an actual analog output safe state is not currently active. Upon activation, a simulated underfill condition will occur. An active poof test will terminate if an actual analog output safe state is activated, or if the analog output proof test timeout value is exceeded.

COMMISSIONING



[Analog output stop proof test]

Command Terminates an active analog output proof test. Upon termination, the normal process will resume and contact 2 will close.

[Analog output proof test interval]

< 1 – 3650 >

(days)

< 1825 > The maximum time interval permitted between analog output proof tests. If exceed and when an analog output safe state is not active, the analog output safety function status will change to W to signal a warning that a proof test is overdue. The status code will remain as NO ERROR.

[Analog output proof test timeout]


< 5 minutes >

< 10 minutes >

< 20 minutes >

< 30 minutes >

< 5 minutes >

If not < Auto timeout off >, the maximum time duration an analog output proof test will remain active. If exceeded the proof test will automatically stop.

[Analog output proof test elapsed time]

(RO)

< 0 – 4,294,967,295 >

(days)

< 0 > The elapsed time since the last analog output proof test or since commissioning if no analog output proof test has been executed.

All Outputs

[Safe state latching behavior]

< Enabled >

< Disabled >

Defined in section 7.3.13.1 “Safety Function Status”.

Behavior of a safe state when the reason for activation no longer applies, to either deactivate when Disabled, or to remain active (latch) until power is cycled when Enabled.

COMMISSIONING


7.4 Configuring the servo gauge To get the gauge fully operational several gauge and tank related

entities must be configured properly (refer to Figure 7-40).

Entity name Entity name (SmartView)

Description

[Displacer type] [Displacer type] (board)

Select the correct displacer type. This will configure several displacer related parameters automatically.

Note: only for density displacers 0815350 and 0815355 configuring additional settings is needed. In this case entities [Displacer weight] and [Displacer volume] need to be configured according to the engraved values.

Note: on the SmartView only the 7 mostly used selections are selectable. For other displacers please use Engauge.

[Measuring range and wire type]

[Wire & drum type] (board)

Select the correct measuring range and wire type. This will configure several wire and drum related parameters automatically. Note: on the SmartView only the 7 mostly used selections are selectable. For other wires and drums please use Engauge.

[Drum circumference] [Drum circum.] (Product level)

Check whether the pre-programmed drum circumference is in accordance with the engraved value of the installed measuring drum. If that is not correct, enter the engraved drum circumference. Note: the unit of the drum circumference is fixed in [mm]!

[Tank top level] [Tank top level] (Product level)

The tank top level must be set for correct compensations. The value you enter now, is overwritten when the level calibration with tank top reference stop is used (refer to 7.6.2).

[Motor limit switch high]

[Motor limit high] (Product level)

This is the highest allowed position for the displacer during normal operation.

[Motor limit switch low]

[Motor limit low] (Product level)

This is the lowest allowed position for the displacer during normal operation.

[Lock test motor limit switch level]

[LT switch level] (Product level)

Sets the highest displacer position during a lock test

[Reference level] [Reference level] (Product level)

Approximate position of the displacer

[Reset board] [Reset TII-SRV] (board)

Reset TII-SRV

COMMISSIONING


Figure 7-40 Tank related level entities 7.5 Alarm settings

Alarms are applicable to all FlexConn sensor functions, like product level, displacer level, water level and density.

It is important to know that 854 alarms, via B and L records are based on the displacer level. The 954 SmartServo FlexLine also follows this principle, so choose the right HART SmartView function and the right Engauge tab when setting the alarm levels.

This is also important when relays of the FII-DO are configured to switch on alarms. To prevent high alarm tripping when e.g. a lock test is issued, one can link a relay to the product level, which will have then a status “good actual stored” when the displacer leaves the product level interface.

COMMISSIONING


7.6 Level calibration

Standard level calibration Make sure the displacer is at the liquid surface. Perform a repeatability test to ensure the displacer is on the product surface Determine the product level by manual dipping. It is essential that the level is as stable as possible.

Note: Make two or three manual dips and compare each reading to ensure the manual dip value is correct.


Description


Enter in this item the manual level.

[Accept reference] [Accept reference] (Product level)

By giving this command, the level value entered in entity [Reference level] is accepted as product level. This will cause an automatic reset.

Level calibration with a tank top reference stop A tank top reference stop is a mechanical device that can hold the displacer at a reproducible position when the displacer is pulled up. This device is placed above the motor limit switch high position. A Honeywell Enraf tank adapter can be provided with such a facility.

1. Follow the procedure as described in section 7.6

2. Determine the tank top position; proceed as follows:


Description

[Calibrate] [Calibrate] (Product level)

With this command the displacer is pulled up until it is halted against the tank top reference. Wait until the displacer is settled.


Read the displacer level value and program that value in entity [Tank top level].

For verification of the level calibration, refer to section 8.8

Do not perform this procedure with a “S0815316 stabigauge 90 mm” or the “S0815360 cptfe 25 mm” displacer, because this will cause damage to the drum.

COMMISSIONING


Level calibration using the top of ball valve If level dipping is not possible, the 954 SmartServo FlexLine can be calibrated using the top of a ball valve as reference point.

Make sure the servo auto test downwards is disabled, else the servo gauge will end up in a SAT failure and will stop measuring level. Refer to section 8.7

Proceed as follows:


Description


The displacer will be raised until it stops against the flange of the level gauge. Caution If a 45 mm displacer is used, immediately stop the Calibrate command as soon as the displacer is above the ball valve, followed by a freeze command. Make sure the displacer is positioned above the ball valve. Close the ball valve.

[Unlock] [Unlock] (Product level)

Unlock the gauge and wait the displacer reaches the top of the ball valve. Calculate the immersion depth of the displacer at the product interface (for a 90 mm displacer use 3 mm; for a 45 mm displacer use 12 mm).


Enter the position of the top of the ball valve with respect to the tank zero adding the immersion depth of the displacer at the product level.

[Accept reference] [Accept reference] (Product level)

By giving this command, the level value entered in entity [Reference level] is accepted as level value and will be shown on the display after the automatic reset.


The displacer will now raise from the ball valve. Let it stop against the flange or give a freeze command. Open the ball valve.


Unlock the gauge. The displacer will now move down till it reaches the level

For verification of the level calibration, refer to section 8.8.2

COMMISSIONING


Interface measurement Interface 3 is used as product / water interface measurement (with interface 2 another interface can be measured). The set point must be set to such a value that half of the displacer volume is immersed in the water and the other half of the displacer volume is immersed in the product. That can be calculated as follows (refer to Figure 7-41 and to Appendix B for detailed displacer information):

( )( ) [ ]1 12 2Setpoint3 0.001* [Displacer weight] - [Displacer volume] + kgproduct waterρ ρ=

where:

[Setpoint3]: set point interface 3 measurement [kg]

[Displacer weight]: displacer weight [g]

[Displacer volume]: displacer volume [cm3]

ρproduct: density of the product [g/cm3]

ρwater: density of water [g/cm3]

Figure 7-41 Calculation of set point Example:

Displacer #0815.343: ø45 mm

Displacer weight: 223 g

Displacer volume: 105 cm3

Volume lower conical part: 3.2 cm3

COMMISSIONING


Height lower conical part: 6 mm

Density product: 0.9 g/cm3

( )( ) [ ]3 0.001* 223 - 105 0.45 0.5 0.12325Setpoint kg= + =

A level offset must be given as the displacer is now immersed for half of the volume in water. On product level the displacer is immersed less. The difference between both immersion depths must be given in the [Primary value offset] of the primary value of the water or interface2 level. (refer to Figure 7-41 (value L3) and to Appendix B for detailed displacer information)

Example:

1. Immersion depth on product level surface: Displaced volume: ([Displacer weight] - Setpoint1) / ρproduct = 15/0.9 = 16.67 cm3 Volume in cylindrical part: 16.67 - 3.2 = 13.47 cm3 Immersion of cylindrical part: 13.47/ πr2 = 13.47/(π*2.252) = 0.85 cm = 8.5 mm Immersion depth on product: 8.5 + 6 = 14.5 mm

2. Separation line product / water: water volume in cylindrical part: ½[Displacer volume] - 3.2 = 52.5 - 3.2 = 49.3 cm3 Water height in cylindrical part: 49.3/πr2 = 49.3/(π x 2.252) = 3.1 cm = 31 mm Separation line product / water: 31 + 6 = 37 mm (from lower end of displacer)

Hence, the [Primary value offset] of the water level PV becomes:

37 - 14.5 = 22.5 [mm] = 0.00225 [m]


Description

[Setpoint 3] [Setpoint 3] (Water level)

Set point for the product / water interface measurement.

[Primary value offset] (Water level)

- General level offset. Used for level offset between interface 1 immersion depth (where the gauge is calibrated) and the product / water interface immersion depth.

[Interface 3] [Interface 3] (Water level)

Set default operation mode to interface 3 (refer to section 0)

COMMISSIONING



Description

[Water interface dip] [Water interface dip] (Product level)

Performs water dip and returns to the default operation once the water level is found: o Servo starts searching for water level o When water level is found it is copied to the Water

Level PV o Servo returns to interface measurement

dependent on the active operational mode [CIU Water interface dip] [CIU Water interface

dip] (Product level)

Performs water dip and stays measuring on water level until an unlock command is given. Used by the CIU: o When CIU sends a GPU “W” record (Water dip)

the BPM module generates the “CIU Water interface dip” command

o Servo starts searching for water level o When water level is found it is copied to the Water

Level PV o Servo stays on water level o CIU sends a GPU “U” record (unlock) o Servo returns to interface measurement

dependent on the active operational mode

7.7 Advanced configuration The servo gauge contains several compensations that can be enabled or disabled. These compensations improve the accuracy of the level measurement

Set point compensations Set point compensations indirectly affect the accuracy of the level measurement.

Set point compensation Description Wire weight Compensates for the wire weight. This compensation must always

be enabled. Unbalance Compensates for the unbalance of the measuring drum and shafts.

Enabling this compensation is highly recommended. This compensation requires performing a balance test first (refer to section 0). This compensation must be enabled for W&M approved applications!

Density Compensates for changing density of the product. This compensation is only useful for small area displacers and when the density of the product is measured (HIMS)

COMMISSIONING


7.7.1.1 Wire weight

The wire weight compensation requires one configuration parameter. This parameter is automatically set correctly when the correct [Measuring range and wire type] is chosen (refer to section 7.4)

When <No measuring range selected> or <Other measuring range or wire type> is selected the wire weight needs to be set manually:

Entity name Default Value Explanation [Wire weight per unit of length] < 0.00025 [kg/m] > Wire weight in kg per meter. The default value

is for stainless steel 316.

7.7.1.2 Unbalance

The unbalance compensation needs a table with the measured unbalance. This table is automatically generated when performing a balance test.

Note: Whenever the drum has been (temporarily) removed from the gauge or the drum is replaced by another one, a new balance test must be performed to update the unbalance table.

COMMISSIONING


Level compensations Level compensations directly affect the accuracy of the level measurement.

Level compensation Description Magnetic coupling Compensates for the slip between inner and outer magnet.

This compensation should be enabled when the gauge measures at different interfaces or when the ambient temperature change exceeds 10°C (18°F). This compensation must be enabled for W&M approved applications!

Magnetic coupling temperature

Compensates for the changes in slip between inner and outer magnet due to temperature. This compensation should be enabled when the ambient temperature change exceeds 10°C (18°F). If this compensation is enabled, the ‘Magnetic coupling’ compensation also needs to be enabled. This compensation must be enabled for W&M approved applications!

Wire temperature Compensates for the thermal expansion of the measuring wire. Enabling this compensation is highly recommended when the vapour temperature is available (VITO). This compensation needs a valid vapour temperature (VITO). This compensation must be enabled for W&M approved applications!

Elongation free wire Compensates for the expansion of the wire because of the weight attached to the wire. This compensation should be enabled when the gauge measures at a different interface than the air-product interface or when the set point of the air-product interface is different from the default 0.208 kg.

Elongation wire on drum Compensates for the expansion of the wire because of the weight attached to the wire for the part of the wire that’s wound on the drum. This compensation should be enabled when the gauge also measures density or measures at various interfaces (e.g. performs water dips).

Tank shell Compensates for the thermal expansion of the tank shell. Enabling this compensation is recommended for tanks higher than 20m. When this compensation is enabled, the ‘Wire temperature’ compensation must also be enabled. This compensation needs a valid vapour and product temperature (VITO).

Hydrostatic deformation Compensates for the hydrostatic deformation of the storage tank. Roof immersion Compensates for snow on the floating roof. Drum temperature Compensates for the thermal expansion of the drum.

Enabling this compensation is highly recommended. This compensation must be enabled for W&M approved applications!

COMMISSIONING


7.7.2.1 Wire temperature

The wire temperature compensation requires one configuration parameter. This parameter is automatically set correctly when the correct [Measuring range and wire type] is chosen (refer to section 7.4).

When <No measuring range selected> or <Other measuring range or wire type> is selected the wire temperature coefficient needs to be set manually:

Entity name Default Value Explanation [Wire temperature coefficient] < 16x10-6 [1/°C] > Wire temperature coefficient. The default value is

for stainless steel 316.

7.7.2.2 Elongation free wire and Elongation wire on drum

These compensations require two configuration parameters. These parameters are automatically set correctly when the correct [Measuring range and wire type] is chosen (refer to section 7.4).

When <No measuring range selected> or <Other measuring range or wire type> is selected the elasticity coefficient (Young’s modulus) and the wire cross sectional area need to be set manually:

Entity name Default Value Explanation [Elasticity coefficient] < 200x109 [N/m2] > Elasticity coefficient (Young’s modulus). The

default value is for stainless steel 316.

[Wire cross sectional area] < 3.1416x10-9 [m2] > Wire cross sectional area (0.25 * π * diameter2)

7.7.2.3 Tank shell

Thermal expansion of the tank shell or stilling well influences the reference position of the 954 SmartServo FlexLine. A compensation method shall be applied so that the total deviation for a temperature change of 10°C falls within the maximum permissible error for the installed SmartServo (according to OIML R85).

The compensation takes expansion of both the product and vapour space area of the tank shell into account.

The SmartServo FlexLine must be equipped with the average temperature option. Both the product and vapour temperature are measured and used in the gauge reference compensation calculations. The tank shell temperature is not a direct measured parameter. It will therefore be calculated from product, vapour and ambient temperatures. For ambient temperature several selections are possible.

COMMISSIONING


For the tank shell compensation, the following entities should be set:

Entity name Default Value Explanation[Tank shell expansion coefficient]

< 16x10-6 [1/°C] > Expansion coefficient of the tank shell. Carbon steel: 12x10-6 [1/°C] Stainless steel: 16x10-6 [1/°C]

[Tank shell reference temperature]

< 20 [°C] > Reference temperature for the tank shell compensation

[Tank shell ambient temperature selection]

< TII-SRV board temperature>

Select the board temperature, magnet temperature, the ambient temperature provided by a local RTD board or the ambient temperature distributed by a CIU.

[Tank shell vapour ambient ratio] < 0.5 > Ratio of vapour and ambient temperatures for calculation of the dry part of the tank shell temperature. Refer to table 4 for more information on the settings in a particular situation.


< 0.875 > Ratio of product and ambient temperatures for calculation of the wet part of the tank shell temperature. Refer to table 4 for more information on the settings in a particular situation.

Standard values for [Tank shell vapour ambient ratio] and [Tank shell product ambient ratio]

Tank type [Tank shell vapour ambient ratio]


Fixed roof tank 0.5 0.875 Fixed roof tank with stilling well *) 1 1 Insulated fixed roof tank 1 1 Floating roof tank with stilling well *) 0 1 Floating roof tank without stilling well 0 1

*) Here is meant that the SmartServo is installed on the stilling well.

The stilling well must be fixed at the tank bottom or at the first ring of the tank shell. If the stilling well is fixed at the top of the tank, then select the values for entity items [Tank shell vapour ambient ratio] from the tank type without stilling well.

The gauge reference height is compensated for both the wet and dry part of the tank shell. The compensated gauge reference height [Compensated tank top] is available as a reference for hand measurements.

Note: For proper reference a hand measurement must use the compensated gauge reference height and subtract a temperature compensated tape value!

COMMISSIONING


7.7.2.4 Hydrostatic deformation

Due to the liquid pressure on the tank shell, the tank shell will bulge. Because of this tank shell deformation, the tank roof moves downwards. Level gauges, which are installed on roof nozzles of fixed roof tanks, are influenced by this movement. The SmartServo FlexLine provides an innage compensation for this deformation. This compensation is dependent on the innage level.

For the hydrostatic deformation compensation, the following entities should be set:

Entity name Default Value Explanation [Hydrostatic deformation level] < 2.0 > This entity contains the innage above which the

compensation becomes effective. Below this innage no compensation is applied

[Hydrostatic deformation factor] < 0 > This entity contains the compensation factor in [m]/[m].

First, the upper reference movement must be found. Then with linear regression, a best fit line can be found as compensation. The outcome of that calculation is used for the [Hydrostatic deformation factor] and [Hydrostatic deformation minimum innage] values.

Calculation of upper reference movement With the following formula (according to OIML R85) the tank shell deformation can be calculated:

where

δh : tank shell deformation [m] D : tank diameter [m] ρ : product density [kg/m3] g : local gravity constant [m/s2] μ : Poisson’s constant (for steel μ=3.3) E : modulus of elasticity (for steel E=206.1 x 109) t : tank shell (ring) thickness [m] h : distance of the liquid surface with respect to a level

below the liquid surface a and b are e.g. the distances of the liquid surface with respect to the top and bottom of the shell segment under investigation.

If the tank shell thickness and internal diameter remains constant over the total height, a=0 and b equals the innage level.

COMMISSIONING


If the rings have a different plate thickness, each ring must be calculated individually, where a and b are the distance of the top and bottom welding seam of each individual ring with respect to the liquid surface. Below follows an example of a calculation for a steel storage tank, diameter 83.82 m, product density of 1000 kg/m3, with the ring heights and wall thickness as per following:

Example of tank ring measures Ring no. Ring height

[m] Wall thickness

[mm] 1 2.743 38.1 2 2.390 36.2 3 2.393 28.9 4 2.390 24.7 5 2.390 20.5 6 2.393 16.3 7 2.390 12.2 8 2.390 11.8 9 2.466 9.5

The local gravity constant is taken as: 9.81288 m/s2 The deformation per ring is (refer to Figure 7-42 for the calculation of the ullage values per ring):

][...

..

....

mm190121640x10x02343

10x594662x

10x1206x33x4812889x1000x8283h

7

3

2

99ring

==

=δ

−

−−

][..

... mm45010x811

46628564x10x02343h 3

227

8ring =−=δ −−

−

][..

... mm72010x212

85642467x10x02343h 3

227

7ring =−=δ −−

−

][..

... mm75010x316

24676399x10x02343h 3

227

6ring =−=δ −−

−

][..

... mm76010x520

639902912x10x02343h 3

227

5ring =−=δ −−

−

][..

... mm77010x724

0291241914x10x02343h 3

227

4ring =−=δ −−

−

][..

... mm78010x928

4191481216x10x02343h 3

227

3ring =−=δ −−

−

][..

... mm72010x236

8121620219x10x02343h 3

227

2ring =−=δ −−

−

][..

... mm90010x138

2021994521x10x02343h 3

227

1ring =−=δ −−

−

COMMISSIONING


The total tank shell deformation then becomes: δh21.945 = 0.19 + 0.45 + 0.72 + 0.75 + 0.76 + 0.77 + 0.78 + 0.72 +

0.90 = 6.04 mm.

The above calculation is for a full tank (level 21.945 m). The tank shell deformation for the same tank, but then with a level of 21 metres is: Likewise, the other ring deformations are to be calculated. If that is done the outcome is:

δh21.000 = 0.07 + 0.33 + 0.61 + 0.67 + 0.70 + 0.72 + 0.73 + 0.68 + 0.85 = 5.36 mm

Figure 7-42 Example steel storage tank with diameter of 83.82 m

COMMISSIONING


The same procedure must be followed for all different levels, with for instance an interval of 1 meter. Then the following table is obtained:

Example of hydrostatic deformation figures Level [m]

Deformation[mm]

Level[m]

Deformation[mm]

Level [m]

Deformation [mm]

0 0 8 0.54 16 2.64 1 0.01 9 0.69 17 3.08 2 0.03 10 0.88 18 3.57 3 0.07 11 1.09 19 4.17 4 0.13 12 1.32 20 4.71 5 0.20 13 1.59 21 5.36 6 0.29 14 1.90 21.945 6.04 7 0.40 15 2.25

The values in this table are the basis for the graph in Figure 7-43

Figure 7-43 Example of hydrostatic deformation correction

Calculate a regression line from the level where the tank shell deviation is approximately 0.5 mm. In this example, the regression line is calculated from 8 meters level till the maximum level. Then, the [Hydrostatic deformation factor] becomes: 0.3869 mm/m. The [Hydrostatic deformation level] is the point where the regression line crosses the X-axis; in this example at 8.1435 m.

Protection and detection settings For proper functioning the servo gauge has several protection mechanisms implemented. For normal operation these protection

COMMISSIONING


mechanisms must be enabled. However, under certain circumstances, they can or need to be disabled (refer to section 9.5)


Default Value

Description

[Wire tension protection]

[Wire tension pr] (Product level)

Enable Enables/disables the wire-protection. The motor is stopped from moving in the wrong direction when the wire tension gets too low or too high. This protects the wire getting out of the drum or from breaking.

If the tension is outside the allowable range for more than 30s an error is generated. The gauge however is still operational.

[Wire rupture protection]

[Wire rupture pr] (Product level)

Enable Enables/disables the wire-rupture-protection. In case the wire protection mechanism detects a low wire tension error (see above) a wire rupture error is generated. The gauge is no longer operational until a board reset is given.

Note: the wire tension protection also needs to be enabled.

[Drum slip detection] - Enable Enables/disables drum slip detection.

If excessive force is applied to the displacer/wire, the inner and outer magnet may slip, causing level jumps of 1/3rd of the drum circumference (~0.11 m).

A detected drum slip results in a ‘Drum slip occurred’ error (6162 on the SmartView). This error can only be cleared by entering maintenance mode (refer to section 11.1).

[Drum slip occurrence

- - Number of detected drum slips since last initialization of the non-volatile ram.

[Motor position errors]

[Motor pos errors] (Displ. Level)

Number of detected motor errors since last reset. The default value will be 1, because the motor position is always checked at start-up.

OPERATION


8 OPERATION 8.1 Repeatability test

With the repeatability test the displacer is raised for approximately 60 mm (2.4”) and then returns to the product surface. During the test, the level dimension and level type on the display are replaced by exclamation marks (!!! !!!) and the status field (I1) changes to [TG]. When the repeatability test is completed, the selected level dimension and level type appears and [TG] is replaced by I1.


Description

[Test gauge] [Test gauge] (Product level)

Performs a repeatability test on the level measurement.

The level reading before and after the test may not differ more than 1 mm (1/16").

8.2 Lock test The lock test command brings the displacer to the position, programmed in entity [lock test motor limit switch level]. During the lock test, the level dimension and level type on the display are replaced by exclamation marks (!!! !!!) and the status field (I1) changes to LT. When the lock test limit switch level is reached, the status field changes into BL (block).


Description

[Lock Test] [Lock Test] (Product level)

The Lock test raises the displacer to the programmed [lock test motor limit switch level] position. Then the gauge goes into block mode (BL). If [Lock test motor limit switch level] is set higher than [Motor limit switch high] the displacer stops at the programmed [Motor limit switch high] position and stays in lock test mode (LT).

The displacer will remain in one of these two positions until an unlock command is given.

8.3 Freeze and block commands Both the freeze and block commands stop the displacer at the current position.

With the freeze command, the displacer remains in its position even when the level reaches the displacer position. Hence, the level cannot be followed and the high, low, high high and low low level alarms cannot be generated.

The block command stops the displacer and, depending on how the block mode (item BM) is set, the displacer will only move up with an increasing level, or the block is cancelled when the level reaches the displacer position.

OPERATION



Description

[Freeze] [Freeze] (Product level)

The displacer remains in its position even when the level reaches the displacer position.

[Block] [Block] (Product level)

The displacer stops at its present position, and depending on the status of entity [Block mode], the displacer will only move up with an increasing level, or the block is cancelled when the level reaches the displacer position

The displacer will remain in its position until an unlock command is given.

Entity [Block mode] must be set (checked) at commissioning (or at a later stage):

Entity name Description

[Block mode] Continuous (default) or Non-continuous

Continuous: when the level reaches the displacer position, the displacer will follow the increasing level

Non-continuous: the block mode is cancelled when the level reaches the displacer position

8.4 Unlock The Unlock command cancels any operational command.


Description


Cancels any operational command.

OPERATION


8.5 Interface measurement The 954 SmartServo FlexLine can measure three different interfaces. Interface 1 (I1) is normally used to measure the product level. Interface 3 (I3) can be used to measure the product / water interface. Interface 2 (I2) is a setting for a special measurement (i.e. interface between two product layers).


Description

[Interface 1] [Interface 1] (Product level)

Interface 1 measurement (based on set point 1); normally used for product measurement.

[Interface 2] [Interface 2] (Interf2 level)

Interface 2 measurement (based on set point 2); setting for special measurement.

[Interface 3] [Interface 3] (Water level)

Interface 3 measurement (based on set point 3); normally used for product / water measurement.

The default setting is on interface 1 (I1). If one of the other two interface measurements is selected, the gauge will remain on that interface measurement till the default measurement (I1) is selected.

8.6 Dip mode When the gauge is in dip mode the displacer will be set at some distance [Dip height] above interface 1 (product surface). After a certain time [Dip interval time] a single product measurement is executed. After the interface has been measured, the displacer will be raised over the dip height. The level, shown on the display and transmitted to the host, will be the dipped level and not the actual displacer position.


Description

[Dip mode] [Dip mode] (Product level)

Activates the dip mode. In dip mode the displacer is positioned at distance [Dip height] above the product and after a time interval [Dip interval time], the product is dipped.

The dip mode is cancelled when one of the interface measurements is selected.

For the dip mode, entities [Dip height] and [Dip interval time] must be set (checked) during commissioning (or at a later stage):


Description

[Dip height] [Dip height] (Displ. level)

In dip mode, the displacer is raised above the product over the dip height distance.

[Dip time interval] <[Dip interv. Time [s]] (Displ. level)

The time in between 2 consecutive interface 1 dips. Minimum value: 1 sec. maximum value: 32767 sec.

OPERATION


8.7 Servo Auto Test The Servo Auto Test (SAT hereafter) is an automatic safety related function meant to reduce the small risk of tank overfill or underfill caused by a failing servo gauge. Immediate after the gauge detects that tank loading has finished a SAT is executed to rule out (or detect) that the gauge is unable to measure the product level due to some failure (e.g. blockage of displacer). The gauge will raise or lower the displacer over a programmable distance and will perform some checks. If the movement is not completed within the expected time or one of the other checks fail, the gauge will retry. If this second try also fails, a third and final attempt is made. Should even the third try fail, the gauge will update the display by removing the measurement unit and display the fail mode. After that the gauge will go into General Fail mode and the PV status code will show one of the SAT failures, e.g. ‘SAT displacer stuck’ (SmartView codes 6172-6180). From this moment on the gauge will respond only to status requests and the reset command.

The SAT will not only be executed immediately after tank loading has apparently stopped, but also at regular configurable intervals.

If the 954 SmartServo FlexLine is used for overfill or underfill protection, the SAT must be enabled (refer to ‘954 SmartServo FlexLine Safety Manual’).

The SAT can also be performed manually by entering one of the commands ‘SAT upwards’ or ‘SAT downwards’.


Description

[SAT upwards] [SAT upwards] (Displ. level)

Performs a SAT upwards. The displacer is raised above the liquid level, the displacer weight and the hysteresis of the system is measured and checked against certain limits.

[SAT downwards] [SAT downwards] (Displ. level)

Performs a SAT downwards. The displacer is immersed in the liquid level and the displacer weight in liquid is measured and checked against certain limits.

OPERATION


The default behaviour of the SAT can be influenced by means of several configuration entities.


Default value

Description

[Autonomous SAT enable]

[SAT enable] (Displ. level)

SAT enable up

When set to 'SAT enable up’ a SAT will be started roughly 1 minute after tank loading has apparently stopped. The SAT will only raise and lower the displacer.

When set to 'SAT enable up + down’ a SAT will be started roughly 1 minute after tank loading or offloading has apparently stopped. The SAT will alternately raise the displacer above the liquid level or lower the displacer beneath the liquid level. For more details refer to 954 SmartServo FlexLine Safety manual.

Furthermore, when one of the SAT enables is selected, the SAT will be executed at regular intervals.

When set to ‘SAT disable’ there will be no automatic SAT at all. The operator can however start a SAT by manually entering the ‘SAT upwards’ or ‘SAT downwards’ command.

[SAT raise height up]

- 0.02 m With this entity the operator can configure the height over which the displacer is raised during the SAT upwards. For a successful SAT the displacer needs to be lifted entirely above the liquid.

[SAT raise height down]

- 0.02 m With this entity the operator can configure the height over which the displacer is lowered during the SAT downwards. For a successful SAT the displacer needs to be immersed entirely in the liquid.

[SAT interval time]

- 60 min With this entity the operator can configure the time between two consecutive SATs. The minimum value is 1 minute, the maximum value is 40320 minutes (28 days).

[SAT weight limit up]

- 0.005 kg During the SAT upwards, the weight of the displacer is measured and checked against the expected weight (entity [Displacer weight]). The measured weight must be smaller than [Displacer weight] + [SAT weight limit up].

[SAT weight limit down]

- 0.005 kg During the SAT upwards, the weight of the displacer is measured and checked against the expected weight (entity [Displacer weight]). The measured weight must be larger than [Displacer weight] - [SAT weight limit down].

OPERATION



Default value

Description

[SAT immersed weight limit]

- 0.180 kg During the SAT downwards, the weight of the displacer in the product is measured and checked against this limit. The measured weight must be smaller than [SAT immersed weight limit].

[SAT frequency limit]

- 120 Hz During the SAT upwards, the hysteresis is of the system is measured. The measured hysteresis must be smaller than [SAT frequency limit].

[SAT intended interface]

- Interface 1 Sets intended interface. The SAT will only be executed when the gauge is measuring the intended interface level.

[SAT invalidate level]

- Disable When set to 'Disable' during SAT • An asterisk ('*') will be shown on the same

position where normally the arrow up/down symbols are displayed.

• When set to ' Enable ', during SAT • An asterisk ('*') will be shown on the same

position where normally the arrow up/down symbols are displayed.

• Both the measurement unit and the measurement type will be set to exclamation marks.

• All level related GPU records will be invalidated.

• Product level PV and Displacer level PV are unaffected.

The behaviour of the function responsible for the level movement detection part of the SAT can be influenced by means of 2 configuration parameters.

Entity name Default value

Description

[SAT sample interval]

< 60 s > The movement detector samples the level in the tank at regular intervals. The operator can configure the time between two consecutive samples by means of this item.

[SAT trip distance]

< 0.003 m > If the absolute level difference between two samples exceeds the trip distance given in this item, then the tank is apparently being loaded or unloaded.

OPERATION


Simple audit trail functionality is implemented by recording several SAT related parameters.


< SAT status > Shows the status of the SAT (idle, 1st attempt, 2nd attempt, 3rd attempt, denied, fail, success).

< SAT level last fail > Level at which a SAT last failed. < SAT last level executed > Level at which the most recent SAT was performed. < SAT minimum level executed >

Lowest level at which a SAT has been performed since NOVRAM initialization.

< SAT maximum level executed >

Highest level at which a SAT has been performed since NOVRAM initialization

< SAT highest number of retries >

Highest number of retries observed during a SAT since NOVRAM initialization.

< SAT number of executed tests >

Total number of SATs performed since NOVRAM initialization.

< SAT time elapsed since last SAT >

Number of minutes elapsed since the most recent SAT successfully completed.

< SAT RTC last fail > Date and time of the last SAT fail. Note: for useful information the Real Time Clock (RTC) needs to be set correctly (refer to section 7.3.4

8.8 Verify level calibration

Verify level calibration against a tank top reference stop When a tank adapter with a tank top reference stop is installed, the level calibration of the 954 SmartServo FlexLine can be checked. Proceed as follows:


Description


With this command the displacer is pulled up until it is halted against the tank top reference. Wait until the displacer is settled.


Request for the tank top value, which was established during level calibration. The level reading from the gauge should not differ more than ±3 mm (±1/8") with the value in entity [Tank top level].


Give an unlock command to cancel the calibrate command.

If the tank top value and the gauge reading differs more than the specified value, the calibration procedure as described in section 7.6.2 should be repeated.

OPERATION


Verify level calibration on top of ball valve If the top of the ball valve is used as reference point, the level calibration of the 954 SmartServo FlexLine can be verified.

Make sure the servo auto test downwards is disabled, else the servo gauge will end up in a SAT failure and will stop measuring level. Refer to section Error! Reference source not found..

Proceed as follows:


Description


The displacer will be raised until it stops against the flange of the level gauge. Caution If a 45 mm displacer is used, immediately stop the Calibrate command as soon as the displacer is above the ball valve, followed by a freeze command. Make sure the displacer is positioned above the ball valve. Close the ball valve.


Unlock the gauge and wait the displacer reaches the top of the ball valve.


Request for the reference level value, which was established during calibration. The level reading from the gauge should not differ more than ±2 mm (±1/16") with the value in entity [Reference level].


The displacer will now raise from the ball valve. Let it stop against the flange or give a freeze command. Open the ball valve.


Unlock the gauge. The displacer will now move down till it reaches the level

If the reference level value and the gauge reading differ more than the specified value, the calibration procedure as described in section 7.6.3 should be repeated.

MAINTENANCE


9 MAINTENANCE 9.1 Preventive maintenance

There are several tests available to check whether maintenance is needed:

• Check bearings

o A short test that checks:

the state of the bearings at one position on the drum

• Measure displacer weight

o A short test that checks:

the displacer weight (force transducer)

• Balance test

o A more elaborate test that checks:

the state of the bearings at several drum positions

the unbalance of the drum

the displacer weight (force transducer)

• Run-down test

o A more elaborate test that checks:

the state of the bearings over a range

obstructions over a range

• Repeatability test

MAINTENANCE


Check bearings command

The check bearings command measures the quality of the bearings at one position on the drum. The command first automatically raises the displacer by a configurable distance, performs a test and writes the result to an entity.


[Check bearings raise height] Raise height of the displacer before performing the actual test.

Note: This value is automatically set at start-up if a specific displacer is selected (entity [Displacer type]) but can be manually adjusted before the command is issued. Make sure the displacer is raised above the product level.

[Check bearings] Raises the displacer and measures the hysteresis of the system [Measured bearing status] Contains the last 10 measurements of the bearings with the latest

on top. The entity contains the status (GOOD, UNCERTAIN or BAD), the measured hysteresis caused by the bearings and the date of the measurement.

The bearing status can be viewed by Engauge:

• If the status of the bearings is BAD, the bearings should be checked and if necessary replaced.

• If the status is UNCERTAIN, the bearings are deteriorating. Please check the bearings and replace them if necessary.

MAINTENANCE


Measure displacer weight The weight of the displacer can be measured with the following procedure:


Description


Raise the displacer for approximately 0.3 m (1 ft) above the product level.

This can be done by setting the entity [Lock test motor limit switch level] to the appropriate level value before the [Lock test] command is issued or by issuing the [Freeze] command when the displacer has reached the appropriate level.

Wait till the displacer is in a complete rest (one or two minutes).

[Measure frequency] [Measure freq] (Product level)

Measure the frequency of the force transducer.

When the measure frequency command is ready: • the status on the display changes from MF

to FR • the displacer level primary value status

code changes from ‘Measure Frequency command active’ into ‘Freeze command active’

• the [Measured frequency status] changes from ‘Command active’ to ‘Command not active’.

[Measured frequency status]

- ‘Command active’ when the gauge is measuring ‘Command not active’ when the command is finished or not started yet.

[Measured weight] - Measured weight including the wire weight [Measured compensated weight]

[MF comp weight [kg]] (Product level)

Measured weight compensated for the wire weight.


Cancel the block / freeze command.

Clean the displacer when the displacer’s weight differs more than 3 g from the value in entity [Displacer weight] or recalibrate the force transducer with the test weights (refer to section 9.49.5. For replacement of the printed circuit boards, motor block or force transducer (refer to section 9.4). After replacement of force transducer or motor block the force transducer requires re-calibration (refer to section 9.5).

The 954 SmartServo FlexLine is an explosion proof instrument with intrinsically safe output/input circuits. Modification to the instrument may only be carried out by trained personnel which is authorized by Honeywell Enraf. Failure to adhere to this will invalidate the approval certificate.

MAINTENANCE


Balance test The balance test measures the unbalance and quality of the bearings over one drum rotation over a configurable number of points. The resulting unbalance data is used for the unbalance compensation for both level and density when enabled (refer to sections 7.7.1 and 10.2.3 ).


Value Range

Default Value

Explanation

[Balance test number of test points]

[BT nr test point] (Product level)

2-32 8 If necessary, change the number of test points.

Note: When the number has been changed to a different value the TII-SRV board needs a reset before the new setting becomes active.

The measuring drum unbalance can be measured by the following procedure:


Description


The Lock test raises the displacer to the programmed [lock test motor limit switch level] position. Then the gauge goes into block mode (BL). If [Lock test motor limit switch level] is set higher than [Motor limit switch high] the displacer stops at the programmed [Motor limit switch high] position and stays in lock test mode (LT).

[Balance test] [Balance test] (Product level)

With this command the balance of the measuring drum is checked. This measurement takes approximately 5 minutes.

When the balance test is ready, the status on the display changes from BT to FR and the displacer level primary value status code changes from ‘Balance Test command active’ into ‘Freeze command active’.


Cancel the balance test / freeze command.

MAINTENANCE


The balance test results in several quality indicators that can be viewed in Engauge and partly on the SmartView.

Entity name Entity name (SmartView) Description

[Balance test result unbalance]

[Drum unbalance [kg]] (Product level)

The drum unbalance should be within 3 grams. When the drum unbalance is more, check for contamination of the drum. If the unbalance is still more than 3 grams replace the drum bearings (refer to section 9.1.2).

[Balance test result average weight]

[Avg meas weight [kg]] (Product level)

Refer to section 9.1.2 when the displacer’s weight differs more than 3 g from the value in entity [Displacer weight].

[Balance test result maximum weight]

[Max unbal weight [kg]] (Product level)

[Balance test result minimum weight]

[Min unbal weight [kg]] (Product level)


[Avg meas freq [kg]] (Product level)

[Measured bearing status]

- Refer to section 9.1.1

The result of the balance test can also be viewed graphically by the diagram viewer in Engauge (Servo Unbalance Diagram).

Figure 9-1 Example of a smooth servo unbalance diagram (16 points)

Figure 9-1 shows an example of a balance test diagram of 16 points. The blue line shows the actual unbalance table in [Hz], while the red lines show the measured hysteresis.

MAINTENANCE


The red lines are only available after a balance test until the next reset. After a reset, only the blue line is still available (see Figure 9-2).

Figure 9-2 Example of a smooth servo unbalance diagram (16 points)

Figure 9-3 Example of a less smooth servo unbalance diagram (16 points)

Figure 9-3 shows an example of a less smooth balance test diagram of 16 points. Compared to the previous diagram, the figure shows hick-ups, indicating issues with the bearings.

MAINTENANCE


Run-down test With the run-down test one can estimate the state of the bearings and the presence of obstructions over a certain range. The command will fill data arrays containing maximum and minimum measured frequency over 140 segments. Those segments are equally distributed between the start and stop position of the test. So, the segment size will be smaller when the range is smaller (with a minimum of 2 cm). By decreasing the range, one can zoom in on a certain part of the range.

Entity name Value Range Default Value Explanation Run down start position 27.0 m Starting position of the run-down

test. The displacer will go up and stop at this position or at motor limit high, whichever comes first.

Run down stop position 0 m Stop position of the run-down test. The run-down test will be terminated at this position or at the product interface, whichever comes first.

Run down Starts the run-down test. When the run-down test is terminated, the gauge will perform the default operation.

The result of the run-down test can only be viewed graphically by the diagram viewer in Engauge (Run Down Diagram).

Figure 9-4 Example of a smooth run-down diagram (segment size ~3 cm)

Figure 9-4 shows an example of a smooth run-down test over a small distance. Because of the small segment size, a 0.34m pattern is visible which is caused by the drum circumference (drum unbalance).

MAINTENANCE


Figure 9-5 Example of a smooth run-down diagram (segment size ~26 cm)

Figure 9-5 shows an example of a smooth run-down test over a large distance. Because of the large segment size, the drum unbalance is no longer directly visible. The unbalance however is indirectly visible, because it causes the lines to be wider apart now. The slope in the measured frequency is caused by the wire weight that increases for lower levels.

Figure 9-6 Example of an erroneous run-down diagram

Figure 9-6 shows an example of an erroneous run-down test over a small distance. The gauge clearly shows issues over the complete range, indicating that this couFigure 9-6ld be bearing issues rather than obstructions.

MAINTENANCE


Repeatability test (refer to section 8.1) If repeatability deteriorates (more than 1 mm) the drum bearings should be replaced (refer to section 0).

9.2 Instrument covers Opening the instrument

The joints between each cover and the housing are waterproof IP65. For this purpose, the covers of the servo, drum compartment and terminal compartment are fitted with O-rings (refer to Figure 9-7). Use a metal rod (like a Tommy bar) for opening the covers.

Check the O-rings to assure water and dust protection. Refer to Appendix A for the dimensions of O-rings.

Closing the compartment covers: In order to ensure that the covers open easily, their screw threads have been greased.

Keep screw threads free from dirt. Grease them lightly with an acid-free grease before closing the instrument. When closing, turn the covers counter-clockwise until the thread clicks into place, then turn clockwise.

9.3 Drum compartment Detailed description, in Figure 9-7 left-side, shows the cross-section of the drum compartment of the medium pressure version and identifies the components. Figure 9-7, right-side, shows the chemical and high-pressure version. The drum shaft, mounted in the drum with a tolerance ring, is inserted into the magnet cap. Two carbon PTFE bearings in the drum shaft bushing support the drum shaft. These bearings should be replaced when repeatability deteriorates.

The drum shaft bushing is kept in position by a circlip. The drum shaft bushing is provided with an internal thread which facilitates removal from the magnet cap.

MAINTENANCE


Figure 9-7 Drum Compartment

Left-side image: Cross section of the drum compartment 954 SmartServo FlexLine medium pressure version.

Right-side image: Cross section of the drum compartment 954 SmartServo FlexLine High pressure version and Chemical version

MAINTENANCE


Removing the measuring drum Removing the drum from the housing requires no tools. Keep the drum, the outer magnet and the outside of the magnet cap thoroughly clean.

To remove the drum, proceed as follows:

1. Issue the Calibrate command to raise the displacer • If applicable close the ball valve and release the pressure gently.

2. Give Unlock command to lower the displacer from tank top position.

3. Issue a Freeze command when the displacer comes within reach.

4. Switch-off the mains.

5. Remove the drum compartment cover.

6. Remove the displacer from the measuring wire. Attach a small weight on the wire to keep it positioned in the groove. Do not damage the measuring wire.

7. Pull out the drum and fix the wire to the drum with a rubber band.

8. Do not kink the measuring wire and handle drum carefully.

If the displacer cannot be accessed through an opening the gauge must be removed from its mounting position:

9. Raise the displacer to maximum height, at least above the ball valve, when present.

10. Switch-off the mains.

11. If applicable close the ball valve and release the pressure gently.

12. Remove the drum compartment cover.

13. Take off the 954 SmartServo FlexLine, raising the displacer above the connecting flange.

14. Remove the displacer from the measuring wire.

15. Pull out the drum and fix the wire to the drum with a rubber band.

MAINTENANCE


Replacing the drum bearings 1. Open the drum cover.

2. Take out the drum shaft bushing.

3. Replace the bearings, refer to figure below

4. Install the bushing.

5. Install drum and displacer.

6. Close the cover.

Figure 9-8 Replacing the drum shaft bearings

Do not grease the carbon PTFE bearings. The drum bearings do not require any lubricant at all.

MAINTENANCE


9.4 The electronic compartment

Detailed description The electronic part of the 954 SmartServo FlexLine requires no special maintenance.

However, a detailed description of the combination of the several parts is given in order to help you in case of software-updates or system enhancements.

Never remove the electronic boards when the mains power is connected to the gauge. It may damage the electronic circuits.

The control hardware is concentrated in the electronic compartment, which contains a minimum number of sub-assemblies. The design of the 954 SmartServo FlexLine is such that it makes replacement and service simple.

The electronic compartment contains the following sub-assemblies (refer to Figure 9-9):

1. Mounting bracket

2. Printed circuit board CAN-SERVO

3. Printed circuit board CAN-PSS

4. Printed circuit board (Optional board: BPM/HAO/TRL2)

5. Printed circuit board (Optional board)

6. Printed circuit board (Optional board)

7. Printed circuit board CAN-HRT

8. Printed circuit board CAN-LCD

9. Stepper motor frame including encoder disc

10. Force transducer

11. Thermistor (Temperature Sensor)

MAINTENANCE


Figure 9-9 Cross section of the electronic and terminal compartment

Dismantling the electronic compartment Note: Whenever the force transducer and/or motor unit have been removed the force transducer must be recalibrated (refer to section Figure 9-5).

To remove CAN-LCD board proceed as follows:

1. Switch off the mains and remove the cover from the electronic compartment.

2. Remove CAN-LCD screws (A) and (B) and carefully disassemble the board from connector (C) by pulling the board slowly (refer to Figure 9-10).

Note: It is not required to remove the CAN-LCD board to access the FlexConn boards & CAN-Servo Board.

MAINTENANCE


Figure 9-10 Position of CAN-LCD screws, clamping bracket, and FlexConn board connectors

To remove FlexConn boards, motor block and force tansducer proceed as follows:

1. Identify how the wiring is routed in general and the positions of option boards if there are any. This is helpful when replacing the components or subassemblies.

2. Remove the clamping bracket by removing the two screws (D) and (E) (refer to Figure 9-10).

3. Remove the connectors (F) of all FlexConn boards (refer to Figure 9-10) and disconnect the grounding cables, if any, only at the connector side. The other tip of the grounding cable will stay fixed on the mounting bracket.

4. Remove all FlexConn boards by rotating them counter clockwise direction using a proper tool on the engagement point between black plastic cover and DIN-rail.

3. Remove the flat cable connecting the motor block to CAN-SERVO.

4. Disconnect the force transducer cable.

5. Secure the motor frame with the transport bracket

6. Remove the two screws holding the force transducer by lifting it slightly in order to release the span wire from the force transducer.

MAINTENANCE


If the motor block needs to be removed, first remove the measuring drum (refer to section 9.3.1)

7. Remove the circlip from the main shaft.

8. Gently remove the motor from its shaft and remove the key.

To remove mounting bracket and CAN-Servo Board proceed as follows:

1. Cut the tie-wraps on the bracket carefully for non-I.S. and I.S (blue) wires.

2. Disconnect the thermistor connector and cut the tie-wrap of the thermistor cable.

3. Unscrew and remove the three screws (G,H and I) securing the mounting bracket, then remove the mounting bracket carefully without damaging any wires. (refer to Figure 9-5)

4. Flip the bracket and remove the four screws of CAN-SERVO board.

Figure 9-11 Position of mounting bracket screws

Note: When reinstalling the mounting bracket, make sure no washer gets in between the mounting bracket and the centrepiece.

Repair of the 954 printed circuit boards

Field repair of the electronic boards is not advised.

MAINTENANCE


9.5 Calibrating force transducer After mounting a new force transducer or another motor-block the force transducer must be calibrated. The frequency of the force transducer must be calibrated with help of a set of accurate test weights of 25 g, 75 g, 150 g and 225 g, all ±0.1 g.

Check the mounting of the 954 SmartServo FlexLine whether it is stable and horizontal.

Use the following procedure for calibration. It is assumed that the 954 SmartServo FlexLine is fully operational. Calibration of an incompletely checked and reprogrammed gauge is not advisable.

If there is no inspection hatch, try to mount the gauge sideways, next to the original 2" flange. Check the availability of ample room to suspend (and move) the test weights (about 60 cm downwards should be enough).

Figure 9-12 Set of test weights (#S1854061)

MAINTENANCE


Switch off the wire protection before calibrating the force transducer:


Default Value

Description



Enable Disable the wire-protection. This prevents that under certain circumstances the 25 g calibration will be aborted.



Enable Disable the wire-rupture. This prevents that under certain circumstances the 25 g calibration will be aborted.


Reset the TII-SRV, which de-activates the wire rupture.

Remove the displacer from the measuring wire and attach the smallest test weight of 25 grams.


Description

[Lock test] [Lock test] (Product level)

Raise the displacer as high as possible until it is in full view, and good accessible.


Send a freeze command to stop the displacer movement. Correct, if necessary temporarily the motor limit high setting, in such a way that the gauge will automatically return to this level after a lock-test command.

[Balance test]] [Balance test] (Product level)

Start a balance test. The 954 SmartServo FlexLine will measure and calculate an average frequency at 25 g over one full drum revolution. Refer to section 0 for more details on performing the balance test.


[Avg meas freq [Hz]] (Product level)

View the average measured frequency after completion of the balance test and note this value for [Frequency 0]. The display will show a FR (freeze) in the lower right corner of the display.

Do not yet reprogram this value in the gauge. Reprogram all values after completion of all the four calibration measurements. Repeat this calibration from for the other 3 test weight combinations:

for Frequency 1 with: (25+75 g),

for Frequency 2 with: (25+150 g),

for Frequency 3 with: (25+225 g).

MAINTENANCE


Remove the test weights from the measuring wire and attach the displacer. Program the measured frequencies:


Description

[Frequency 0] [Frequency 0 [Hz]] (Product level)

Program frequency 0, measured with test weight of 25 g.






Program frequency 3, measured with test weight of 250 g



Enable wire tension protection.

[Wire tension rupture]


Enable wire rupture protection.


Reset TII-SRV to activate the new settings.

MAINTENANCE


Note: A faster method of calibration is using the commands [Measure frequency 0], [Measure frequency 1], [Measure frequency 2] and [Measure frequency 3] commands instead of the balance test command. The measured values are automatically entered in the corresponding entities ([Frequency 0], [Frequency 1], [Frequency 2] and [Frequency 3]). This method may not be followed when your gauge is used for density measurement via the density displacer.


Description

[Lock test] [Lock test] (Product level)

Raise the displacer as high as possible until it is in full view, and good accessible.


Send a freeze command to stop the displacer movement. Correct, if necessary temporarily the motor limit high setting, in such a way that the gauge will automatically return to this level after a lock-test command.

[Set to maintenance mode]

[Maintenance mode] (Product level)

Go into maintenance mode and do not enter any command which is not specified below.

[Measure frequency 0]

[Measure F0] (Product level)

Measure the frequency of the force transducer with a 25g weight.

When the measure frequency command is ready, the status on the display changes MF to FR, the displacer level primary value status code changes from ‘Measure Frequency command active’ into ‘Freeze command active’ and the [Measured frequency status] changes from ‘Command active’ to ‘Command not active’.










[Measured frequency status]

[MF Status] ‘Command active’ when the gauge is measuring ‘Command not active’ when the command is finished or not started yet.



Enable wire tension protection.



Enable wire rupture protection.


[Operational mode] (Product level)

Restart in operational mode

MAINTENANCE


9.6 Synchronizing the reference encoder After the installation of a new motor block, the internal reference encoder must be synchronized to the position of the reference encoder and the gauge starts with an error with status code e.g. ‘Find positions failed offset to big’ (SmartView code 6158). The following procedure will solve this issue.


Description



Go into maintenance mode and do not enter any command which is not specified below.

[Find reference encoder position]

[Find ref encoder] (Product level)

The 954 SmartServo FlexLine finds its encoder position. Wait approximately 20 seconds.




DENSITY OPTION


10 954 Density option

10.1 Introduction

Functional description A special software package for density measurement is available for the 954 SmartServo FlexLine gauge. This optional package offers the possibility to measure tank density profiles and interface density profiles.

Tank Profile density measurement offers the possibility to measure the density at up to fifty spots in the product. The individual measurement locations are equally divided over the complete product height.

Interface Profile density measurement offers the possibility to access the density stratification at or around a specific interface-layer.

Tank profile density measurement offers high absolute density accuracy, while Interface Profile measurement offers high position accuracy.

In principle, tank profile density measurement realises the high absolute density accuracy by measuring over a complete drum rotation to minimize the influence of the unbalance of the drum. The measurement offers the possibility though to measure only at one drum position. By enabling the unbalance compensation, the measurement time can be reduced while maintaining a high absolute density accuracy.

Interface profile density measurement always measures on only one drum position. The accuracy of the density measurement can be increased by enabling the unbalance compensation.

After completion of a density profile measurement an average density is calculated.

Notes:

Application of servo density measurement is restricted to 'clean', non-viscous products.

Absolute inaccuracies of less than 5 kg/m3 (0.31 lbs/ft3) for the Tank Profile density measurement, and

10 kg/m3 (0.62 lbs/ft3) for the Interface Profile measurement can be accomplished if the gauge is properly installed, calibrated and maintained.

DENSITY OPTION


Principle of operation The 954 can be used for density measurement if the servo level gauge is equipped with the optional software. In addition to the software a density displacer with an increased volume (200 cm3) must be used.

Two standard stainless-steel density displacers, with 43 mm and 90 mm outer diameter, are available. They are applicable for a maximum working pressure of 20 bar (290 psi).

To obtain the average observed density, the displacer is positioned at up to 50 different positions, equally divided over a specified measuring height. The apparent weight of the displacer is measured. Knowing the volume and the weight of the displacer, the observed density can be calculated. An average density will be calculated over all measured densities. The density data is transferred via the Honeywell Enraf field bus.

10.2 Commissioning

Installation on the tank Correct installation and calibration of the 954 is essential to obtain maximal accuracy of the density measurements.

Check if the gauge is correctly installed and commissioned.

Check the stability of the mounting of the 954. As all position changes of the 954 perpendicular on the shaft axes will introduce a density deviation, the horizontal angle should not exceed ± 0.5 °.

Check whether the installed software supports density measurement. This can be done by checking entity [Functional licensed options] on the Miscellaneous tab in Engauge. Field 01 must be set to True.

Calibration of the 954 level gauge Perform a balance test to check the unbalance of the measuring drum. Refer to section 9.1.3.

Note:

The drum unbalance should be within 3 grams. If the drum unbalance is more, check the drum for contamination. If the unbalance is still more than 3 grams, replace the drum bearings and check again. For details refer to section 9.1.2, 9.1.3 and 0.

Calibrate the force transducer. This is required for the most accurate density measurement result. Refer to section 9.5.

Check the displacer weight after the calibration of the force transducer. Refer to sections 9.1.2 and 9.1.3.

It is recommended to weigh the displacer with the balance test and then check the average unbalanced weight.

DENSITY OPTION


Note: The measured displacer weight should not differ more than 0.1 grams from the engraved displacer weight (0.1 gram measuring error by the displacer weight results in a density error of 0.5 kg/m3). If it is more than 0.1 grams, re-calibrate the force transducer and/or check the drum unbalance.

Setting of density items The items mentioned in this section are common for the Tank Profile and Interface Profile measurement.


Description

[Displacer weight] [Displacer weight] (Product level)

Units: [gram]. Enter the weight of the displacer. This is engraved on the displacer.

[Displacer volum]e

[Displacer volume] (Product level)

Units: [cm3]. Enter the volume of the displacer. This is engraved on the displacer.

[Number of density levels]

- Number of levels where a density measurement is performed (1-50). The default value is 10.

Wire cross sectional area]

- Units: [m2]. Wire cross sectional area (0.25 * π * diameter2). The default value is 3.1416x10-9 [m2].

Note: This parameter is automatically set correctly when the correct [Measuring range and wire type] is chosen (refer to section 7.4.

[Density compensations]

- Enables or disables compensations on the density calculations:

• Tilt: compensates for dynamic tilting of the gauge by measuring the displacer weight in vapour before the actual density measurements. Note the compensation will only be performed if the displacer weight can be measured in vapour, so there must be enough space. TP requires at least a full drum rotation +0.25m. IP requires 0.25m.

• Unbalance: compensates for the unbalance of the drum. This compensation requires a valid unbalance table (refer to section 9.1.3)

• Displacer volume: compensates for hydrostatic pressure on the displacer and thermal expansion of the displacer.

[Liquid surface pressure]

- In high pressure applications (spheres or bullets) this entity should reflect the pressure in the storage tank. The default value is atmospheric pressure (101325 Pa).


Reset the TII-SRV to activate the settings.

DENSITY OPTION


Tank profile measurement Interface Profile measurement

Figure 10-1 Tank Profile and Interface Profile density measurement

Settings for a tank profile measurement (command Tank profile) The following entities must be programmed before the 954 SmartServo FlexLine gauge can perform a Tank Profile density measurement.

DENSITY OPTION



[Tank profile start distance]

Refer to Figure 10-1. The distance from the liquid surface till the middle point of the highest density measuring point. For a good density measuring result, the value must be at least 0.3 m (1 ft).

[Default tank profile stop level]

Refer to Figure 10-1. The middle point of the lowest density measuring point. For a good density measuring result, the value must be at least 0.2 m (8") above the motor limit switch low.

[Density scan direction] Determines the direction in which a tank profile (or interface profile) is measured.

Scan direction down: from product surface downwards Scan direction up: from bottom upwards

Note: When also water bottom is measured first via the water dip command, it is advised to set the scan direction upwards. Then the combined dip command directs the displacer downwards for water measurement, and on the way back, density is measured.

[Number of tank profile drum balance points]

The number of measurement points for one density measurement equally distributed over one drum rotation.

[Tank profile method] Determines the measurement method: • Multi over drum: measures at multiple points of one drum

rotation to get an accurate density measurement. This method is the most accurate.

• One drum position: measures only at one drum position. For an accurate density measurement, the unbalance compensation must be enabled. This requires a valid unbalance table (refer to section 9.1.3).

[Reset board] Reset the TII-SRV to activate the settings.

Settings for an interface profile measurement (command Interface profile) The following entities must be programmed before the 954 SmartServo FlexLine gauge can perform an Interface Profile density measurement. Refer to Figure 10-1. The entities do not require a reset command.


[Interface profile start level]

Refer to Figure 10-1. An interface profile density start level measurement can be performed at any location in the tank. [Interface profile start level] specifies the highest interface level (so that is independent of the density scan direction).

[Interface profile stop level]

Refer to Error! Reference source not found. An interface profile density start level measurement can be performed at any location in the tank. [Interface profile stop level] specifies the lowest interface level (so that is independent of the density scan direction).

[Density scan direction] Determines the direction in which an interface profile (or tank profile) is measured.

Scan direction down: from [Interface profile start level] downwards Scan direction up: from [Interface profile stop level] upwards

DENSITY OPTION


Corrections Entity [Air density] contains the ambient air density and is used to present the measured observed density as density in vacuum. If the density value is required as density in air, then entity [Air density] must be set to 0.


[Air density] The default value is 1.225 [kg/m3]

For density in vacuum: use the approximate air density in this entity. For density in air: set this entity to 0.

10.3 Operation

Manual input For the tank profile measurement, the default density stop distance can be changed by entity [Tank profile stop level]. After a power down, or reset of the level gauge, the manual input data is lost.


[Tank profile stop level] If the level value for this entity is higher than [Default tank profile stop level], this value is used as stop level instead.

Data items, commands and error codes Below, a summary is given of the data items, commands and applicable error codes. The following commands are available:


[Interface profile] Starts an interface profile measurement. The density measurements are equally divided between distance [Interface profile start level] to distance [Interface profile stop level]. Both start and stop level need to be in the product.

[Tank profile] Starts a tank profile measurement. The density measurements are equally divided between [Tank profile start distance] below the liquid surface and distance [Tank profile stop level] (or [Default tank profile stop level], whichever is higher).

[Density water dip] Starts a tank profile measurement followed by a water level measurement. The density scan direction is no longer configurable and downwards.

[Water density dip] Starts a water level measurement followed by a tank profile measurement. The density scan direction is no longer configurable and upwards.

Entity [Density data] contains all information of the individual density measurements. This entity has the following fields:

DENSITY OPTION



[Index] Index 0 is the level closest to the bottom [density status byte] Refer to section 10.4.2 [density value] Measured servo density value; the calculated density at the

corresponding level value. [level status byte 0] Refer to section 10.4.2 [level status byte 1] Refer to section 10.4.2 [level value] Density innage level; the calculated level midpoint at which the

corresponding density will be measured. The calculated average density and applicable status codes are available in the primary value of the density function.

10.4 Maintenance and trouble shooting

Maintenance With the density option it is recommended to check (once or twice a year) the level gauge regularly by means of a balance test (refer to section 9.1.3).

Trouble shooting Besides the primary value status code, data items from the density measurement contain one or two status bytes, which also gives valuable information. These bytes are readable ASCII characters. However, most of them are bit coded. Appendix C contains an ASCII table for conversion of the status bits into the actual status.

An example for a bit coded status byte:

one (of the) status bytes reads: F;

written out in bits (refer to Table 14-1): 0100 0110;

(b7=0, b6=1, b5=0, b4=0, b3=0, b2=1, b1=1, b0=0).

Bit 7 is always a ‘0’ and bit 6 is always a ‘1’ to avoid ‘control’ characters.

Look up the relevant status byte in this section to determine the meaning of the bits which are set to ‘1’. Only the bits set to ‘1’ represent an actual status.

DENSITY OPTION


Level status bytes

level status byte 0 level status byte 1 Bit Description Bit Description 0 general fail / default setting 0 trajectory exceeds level product level;

[Tank profile start distance] too small (TP only)

1 no valid product level 1 density trajectory stops below stop level (TP only)

2 level / trajectory exceeds motor limit high level

2 no valid start or stop levels (IP only)

3 level / trajectory exceeds motor limit low level

3 0

4 0 4 0 5 0 5 0 6 1 6 1 7 0 7 0

Density status byte

Bit Description 0 general fail / default setting 1 measurement not completed 2 0 = Tank Profile, 1 = Interface Profile 3 no measuring point or measuring point out of range4 level / trajectory exceeds motor limit level5 0 6 1 7 0

TROUBLE SHOOTING


11 TROUBLE SHOOTING

11.1 Problems with displacer movement If the displacer is not running freely, for instance stuck against a stilling well, it can be controlled manually.

Note: Be aware that measuring wire is unrolled from the measuring drum. When the measuring wire is not kept at tension, the result will be an uncontrolled wire movement which results in the worst case in the loss of the measuring wire.


Description



Go into maintenance mode.

[Go down] [Go down] (Product level)

Go down for approximately 200 mm (8"). The displacer will move downwards until the freeze command is given.


Give the freeze command which stops the displacer




When hereafter the displacer is free, and the weight is too high, the force transducer must be recalibrated. When the measured displacer weight is too far out of range, the gauge is probably not levelled within 2°. Then, improve the stability of the construction on which the gauge is mounted.

11.2 Status Codes The 954 SmartServo FlexLine provides information on the status of the gauge. This might be errors or warnings, but the gauge can also provide informational messages, e.g. to show that the gauge is in performing a balance test.

On the SmartView, this information is visible as a code behind the TII-SRV functions. In Engauge the display description is shown in the status code of the Primary Value.

The primary value status shows the actual status. Additionally, each function has a [Status history uncertain] and [Status history bad] list that contains the last 10 warnings and errors that have occurred since the last reset.

Note: if the actual status is GOOD, there is no actual error or warning active, even though the history lists might show errors or warnings!

TROUBLE SHOOTING


Informational status codes Numbers in the range 6336-6911 are informational status codes. Informational codes have a lower priority than warning or error codes, so if a warning or error is active the informational status isn’t visible.

Status code (SmartView)

Description (Engauge)

Remarks

6346 Lock to level command active

6347 Lock test to level command active

6348 Test command active

6349 Density water dip command active

6350 Water density dip command active

6351 Check bearings command active

6352 Go up command active

6353 Test gauge command active

6354 Tank profile command active

6355 Measure frequency command active

6356 Interface profile command active

6358 Go down command active

6359 Calibrate command active

6361 Lock test command active

6362 Interface 1 command active



6365 Block command active

6366 Freeze command active

6367 Dip mode command active

6368 Balance test command active

6369 Run down command active

6370 Maintenance mode active

6371 Motor limit high exceeded

6372 Motor limit low exceeded

6373 Firmware update busy

6398 Motor limit reached

TROUBLE SHOOTING


Warnings Numbers in the range 6272-6335 are warning codes. Warnings will set the status of the Primary value to UNCERTAIN.



Remarks

6273 No valid product level for compensation

E.g. because the displacer is not measuring product level. Please check the Primary value of the Product level.

6274 No valid temperature for tank shell compensation

One of the temperatures needed for the tank shell compensation is not available (refer to section 7.7.2.3). Please check the vapour and product temperatures on the FCI-HRT or FII-RTD.

6275 Balance test number of valid test points too low

The unbalance table has too few valid entries. Can appear when the unbalance compensation for set point or density is enabled. Perform a balance test to provide a new table (refer to sections 7.7.1 and 9.3.1).

6276 Balance test number of valid test points too high

The unbalance table has too many valid entries. Can appear when the unbalance compensation for set point or density is enabled. Perform a balance test to provide a new table. (refer to sections 7.7.1 and 9.3.1)

6277 No valid vapour temp. for wire temp. compensation

Please check the vapour temperature on the FCI-HRT.

6278 No valid magnet temp. for magnet temp. compensation

Please check the magnet temperature status (Board Specific).

6279 No valid product level for hydrostatic deformation comp.

E.g. because the displacer is not measuring product level. Please check the Primary value of the Product level.

6280 No valid displacer temp. for volume compensation

Please check the product temperature on the FCI-HRT.

6283 No valid product level or magnet temp. for drum temp. compensation

Please check the magnet temperature status (Board Specific) or the Primary value of the Product level.

6285 RIC configuration parameters not commissioned

6286 Product level below RIC minimum level

6287 Error getting HART dynamic variables entity device address 11

RIC warning


RIC warning


RIC warning

6290 Wrong HART units device address 11

RIC warning


RIC warning

TROUBLE SHOOTING




Remarks


RIC warning

6293 Bad HART status device address 11

RIC warning


RIC warning


RIC warning

6296 Weight in vapor bad for density tilt compensation

Errors Codes in the range 6130-6271 are error codes. Errors will set the status of the Primary value to BAD.



Remarks

6130 Frequencies F0..F3 not commissioned

Commissioning error (refer to section 7.4).

6131 Drum circumference not commissioned


6132 Motor limits high or low not commissioned


6133 Tank top level not commissioned Commissioning error (refer to section 7.4).

6134 Reference level not commissioned


6144 Frequency sensor failed to start up

Hardware error of the frequency sensor.

6146 Find positions failed encoder problem

Hardware error of the reference encoder.

6148-6154 Sensor frequencies out of range Calibration of the frequency sensor failed. Please check [Frequency 0] - [Frequency 3].

6156 Frequency coefficients out of range

Calibration of the frequency sensor failed.

6158 Find positions failed offset to big The displacer level is unreliable. The reference encoder needs to be calibrated in maintenance mode (refer to section 9.6)

6159 Find positions failed wire tension error

The reference encoder could not be checked because the wire tension is too low or too high. Please check the wire and displacer.

6160 Find positions failed no space The motor limits are too close to each other. Find positions needs 10mm up or downwards.

TROUBLE SHOOTING




Remarks

6162 Drum slip occurred Probable slip of the inner and outer magnet. This can only be resolved by entering and exiting maintenance mode. Please check displacer level before continuing, there might be an offset of (multiples of) 11 cm. Refer to sections 7.7.3 and 11.1.

6164 Resetting frequency sensor Frequency sensor failed to start-up but is recovering. Please wait a short while.

6170 Wire rupture Please check the wire and displacer. Refer to section 7.7.3.

6172 SAT displacer weight out of range

SAT failure (refer to section 8.7). Please check the [SAT raise height up] or check the displacer weight in air (refer to sections 9.1.2 and 9.1.3.)

6174 SAT frequency difference too large

SAT failure (refer to section 8.7). Please check the bearings (refer to sections 9.1.1 and 9.1.3).

6176 SAT displacer immersed weight out of range

SAT failure (refer to section 8.7). The displacer weighs too much in the product. Please check the [SAT raise height down].

6178 SAT displacer stuck SAT failure (refer to section 8.7). The displacer is not able to move freely.

6182 Frequency out of range Sensor frequency larger than 25 kHz. Please check the frequency sensor if this error is persistent.

6183 Invalid drum circumference Commissioning error (refer to section 7.4).

6184 Unable to get data from novram 6185 Motor limit high range exceeded The displacer is above the motor limit

high position. Move the displacer down (refer to chapter 11.1) or adjust the motor position limits. Note: please check if the drum circumference is set to a correct value (should be approximately 340 mm).

6186 Motor limit low range exceeded The displacer is below the motor limit low position. Move the displacer up (refer to chapter 11.1) or adjust the motor position limits. Note: please check if the drum circumference is set to a correct value (should be approximately 340 mm).

6187 Motor exit data crc corrupted 6188 Motor limits high and low

distance too small Commissioning error. The motor limits are too close to each other. The distance needs to be at least 25 mm.

TROUBLE SHOOTING




Remarks

6191 Encoder LED pin malfunction Hardware error. Malfunction of the LED of the reference encoder.

6208 Wire tension too high The wire tension is too high. The gauge will resume functioning when the wire tension issue is resolved (by e.g. moving the displacer down). Refer to sections 7.7.3 and 11.1.

6209 Wire tension too low The wire tension is too low. The gauge will resume functioning when the wire tension issue is resolved (by e.g. moving the displacer up). Refer to sections 7.7.3 and 11.1

6210 Density displace declined 6211 Boot self test failed 6212 Density license not available

APPENDIX A


12 Appendix A: Article and part numbers No. Description Part number

2

Measuring drum 27m incl. shaft and AISI316 wire S0854962 Measuring drum 37m incl. shaft and AISI 316 wire S0854963 Measuring drum 150m AISI 316 wire S0854325 Measuring drum 47m AISI316 0,2mm S0954303

4 Set bolts & rings 6x M6x16 - 854 ATG S0854941 5 Set bolts & rings 3x M10x25 - 854 ATG S0854942 6 Main shaft with magnet - 854 ATG S0854340 7 Round Key for Main shaft S6576001 9 Terminal compartment cover - 854 ATG S0186020 12 Terminal block assembly -954 S0954375 16 Mounting Bracket + Clamping Bracket + Fasteners TBD 17 Fuse set for 854 gauges (10x 250mA 50V + 10x 1A 250V) S0854970 27 Pull Wire S0854151 28 854 Force transducer S0854485

30 Front cover + window - 854 ATG S0854952 Anti-seize paste (Not available for US) S4000015

31 Motor connection board S0894601 32 Motor unit S0854957 35 Set of 2 Ball bearings C 8.0x 22 x 7.0 S2100418

39

Carbon filled PTFE, weight 223 g.; Diameter 25 mm (C/223/CT/025) S0815360 Carbon filled PTFE, weight 223 g.; Diameter 45 mm (C/223/CT/045) S0815343 Carbon filled PTFE, weight 223 g.; Diameter 90 mm (C/223/CT/090) S0815344 Carbon filled PTFE, weight 223 g.; Diameter 110 mm (C/223/CT/110) S0815345 AISI 316; weight 260 g.; max pressure 20 barg; diameter 45 mm ( C/260/S/045) S0815355

AISI 316; weight 260 g.; max pressure 20 barg; diameter 90 mm ( C/260/S/090) S0815350

40

Measuring wire INVAR 40 m S0802841 Measuring wire Tantalum 30 m S0802851 Measuring wire AISI 316 30 m S0802801 Measuring wire AISI 316 40 m TBD Measuring wire AISI 316 43 m TBD Measuring wire AISI 316 48 m TBD Measuring wire AISI 316 150 m S0802806 Measuring wire Hasteloy 30 m S0802861 Measuring wire Tungsten 30 m TBD Measuring wire Tungsten 40 m TBD Measuring wire Tungsten 43 m TBD Measuring wire Tungsten 45 m TBD

APPENDIX A


No. Description Part number

43 Drum bearing set incl. circlips, bushing and drum shaft S0854953 Set of 20 pcs. drum bearings incl. circlips S0854955

46 Drum compartment cover - 854 ATG (M version) S0185583

59

FlexConn PCB: Relay output(FII-DO) 4xSPDT S0690904 FlexConn PCB: Power supply (PSS) S0690915 FlexConn PCB: RTD Spot (FII-RTD) S0690910 FlexConn PCB: RTD Multi elements (FII-RTD) S0690920 FlexConn PCB: HART / AO 4-20 mA (HCI) S0690911 FlexConn PCB: BPM field comm. (HCI-BPM) S0690921 FlexConn PCB HART devices+HIMS Dens.calc. S0690967 FlexConn PCB SPARE:HART+VITO S0690614 FlexConn PCB SPARE:HART+VITO+HIMS S0690615 FlexConn PCB SPARE: HCI-TRL 2 S0690623 FlexConn PCB SPARE: CAN-SIL S0954609 CAN- SRV S0954600

60 HART SmartView display (repair kit) S0948801 61 CAN- LCD S0954602 102 Drum compartment cover - 854 ATG (C + H version) S0185814 102 O-ring set - 854 ATG S0854966

APPENDIX A


APPENDIX B


13 Appendix B: Additional information on displacers

Displacer type Part number Displacer area [m2]

Displacer volume [cm3]

Displacer weight [kg]

Carbon filled PTFE ø 25 mm ø 45 mm ø 90 mm ø 110 mm

S0815360 S0815343 S0815344 S0815345

0.00049 0.0016 0.0064 0.0095

105 105 105 105

0.223 0.223 0.223 0.223

Density displacer (stainless steel)

ø 90 mm ø 43 mm

S0815350 S0815355

0.0064 0.0016

approximately 200; exact value is engraved on

displacer

approximately 265; exact value is engraved on

displacer

APPENDIX B


SALES & SERVICE


14 Appendix C: ASCII table

Table 14-1 ASCII table

SALES AND SERVICE

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

4417340 Rev.1.0 March 2019 2019 Honeywell International Inc.

Shanghai City Centre, 100 Jungi Road Shanghai, China 20061 www.honeywellprocess.com

For service-related questions, contact: Technical Assistance Centre Phone: +1 800 423 9883 or +1 215 641 3610 E-mail: [email protected] Copyright © 2019 - Honeywell All rights reserved. No part of this manual may be reproduced in any form, by print, photoprint, microfilm or any other means without the written permission from Honeywell.

Service Manual 954 SmartServo FlexLine - Honeywell Process

Documents

Transcript of Service Manual 954 SmartServo FlexLine - Honeywell Process