Honeywell FlexLine SmartServo 954 User manual

Installation Manual
954 SmartServo FlexLine

Part No: 4417341 Revision 10 Installation Manual 2
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.: [phone]
Fax: [phone]
E-mail: [e-mail]
Website: www.honeywellprocess.com

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About this manual
This manual provides information related to installation of the 954 SmartServo FlexLine.
For servicing of the device refer to the 954 SmartServo FlexLine Service Manual listed below in
References.
For Safety instructions and procedures refer to the 954 SmartServo FlexLine Safety manual listed
below in References.
Introduction
The 954 SmartServo FlexLines an automatic tank gauge measuring the surface or interface level of
crude oil or derived products stored in a bulk storage tank. Typically those storage tanks are available
on terminals, production plants and refineries in the petro chemical, oil and gas industry. The
environment on those sites is typically explosion hazardous.
The end user will typically use the 954 SmartServo FlexLine together with a Terminal Inventory
System for custody transfer operations, therefore Weights and Measures legislation is applicable.
The 954 SmartServo FlexLine is basedon the modular FlexConn board architecture. EveryFlexConn
board supported in this device is described in detail.
Revision History
954 Installation Manual (This document)
4417341
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9th November 2018 (1st Release)
4417341
01
20th November 2018 (Updated the document)
4417341
02
22nd November 2018 (Updated the document)
4417341
03
23rd November 2018 (Finalized the document)
4417341
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29th November 2018 (Added Relay Output Section)
4417341
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29th November 2018 (Updated Pmax on Relay Output)
4417341
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10th December 2018 (Updated pages 21 and 32)
4417341
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10th January 2019 (Added FM information on page 16)
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17th January 2019 (Added temperature range on page 16)
4417341
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23rd January 2019 (Added I/O text to tables on page 35, 36, 38 & 39)
4417341
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12th March 2019 (Added CSA information on page 16)

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References
The following list identifies publications that may contain information relevant to the information in
this document.
4417340
1
954 Service Manual
4417342
1
954 Safety Manual
Patents
The Honeywell 954 SmartServo FlexLine servo-based level gauge is covered by the following
patents:
US2017307461 (A1) 2017-10-26, US2018058960 (A1) 2018-03-01
WO2017062413 (A1) 2017-04-13, WO2018044518 (A1) 2018-03-18

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Contents
1. GENERAL ......................................................................................................................................................................... 8
Using this Installation Guide ................................................................................................................................... 8
Related Documents................................................................................................................................................. 8
Trademarks ............................................................................................................................................................. 8
Contact.................................................................................................................................................................... 8
2. SAFETY AND SECURITY .................................................................................................................................................... 9
General.................................................................................................................................................................... 9
Safety Conventions ................................................................................................................................................. 9
WARNINGS ...................................................................................................................................................... 9
CAUTIONS........................................................................................................................................................ 9
Safety Instructions................................................................................................................................................. 10
2.3.1. Safety Instructions ............................................................................................................................................ 10
2.3.2. EC Declaration of Conformity (for EU) .............................................................................................................. 10
2.3.3. Control Drawings for FM & CSA ........................................................................................................................ 10
2.3.4. Users.................................................................................................................................................................. 10
2.3.5. Additional Information...................................................................................................................................... 10
2.3.6. Environmental Conditions................................................................................................................................. 10
Liability .................................................................................................................................................................. 11
Labels .................................................................................................................................................................... 11
Personal Safety...................................................................................................................................................... 12
Warnings and Cautions ......................................................................................................................................... 12
2.7.1. General.............................................................................................................................................................. 12
General Precautions.............................................................................................................................................. 14
Accordance to Regulations.................................................................................................................................... 15
2.9.1. Explosion Safety ................................................................................................................................................ 15
3. PRINCIPAL OF SERVO MEASUREMENT.......................................................................................................................... 17
Principle of Measurement .................................................................................................................................... 17
3.1.1. Level Measurement .......................................................................................................................................... 18

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3.1.2. Interface between two Products ...................................................................................................................... 18
3.1.3. Relative Density................................................................................................................................................. 18
4. MECHANICAL INSTALLATION ........................................................................................................................................ 19
Preparation for Transportation of the Gauge....................................................................................................... 19
Process Connection............................................................................................................................................... 19
Orientation of 954 SmartServo FlexLine Gauge on Tank...................................................................................... 20
Bolts ...................................................................................................................................................................... 21
Mounting a Pressure Gauge Set............................................................................................................................ 21
Grounding ............................................................................................................................................................. 22
5. ELECTRICAL INSTALLATION ........................................................................................................................................... 23
General.................................................................................................................................................................. 23
Grounding ............................................................................................................................................................. 23
Safety .................................................................................................................................................................... 24
5.3.1. General Relative Density................................................................................................................................... 24
Installing the Cable Glands and Stopping Plugs .................................................................................................... 25
5.4.1. Cable Glands...................................................................................................................................................... 25
5.4.2. Unused Cable Inlets .......................................................................................................................................... 25
Installing the Glands, Conduits and Stopping Plugs.............................................................................................. 26
5.5.1. Conduits ............................................................................................................................................................ 26
5.5.2. Unused Cable Inlets .......................................................................................................................................... 26
Electrical Connections........................................................................................................................................... 27
5.6.1. Grounding ......................................................................................................................................................... 27
5.6.2. Connections ...................................................................................................................................................... 27
Finishing Installation ............................................................................................................................................. 39
5.7.1. Assembling the Terminal Block and Board Compartment’s Lids ...................................................................... 39
External Fusing...................................................................................................................................................... 40
Cable Glands / Conduit ......................................................................................................................................... 40
Grounding ......................................................................................................................................................... 41
Appendix A........................................................................................................................................................................ 42
Appendix A (Continuation)................................................................................................................................................ 43
Appendix B ........................................................................................................................................................................ 44

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Figure
Figure 1 Identification Label with Safety Note on the 954 SmartServo FlexLine ................................................................. 11
Figure 2 Unlocking the 954 SmartServo FlexLine Motor ...................................................................................................... 14
Figure 3 Measuring Drum ..................................................................................................................................................... 15
Figure 4 Principle of Measurement ...................................................................................................................................... 17
Figure 5 Orientation of the Gauge on a Tank (top view) ...................................................................................................... 20
Figure 6 Mounting a Pressure Gauge Set on a 954 SmartServo FlexLine Gauge.................................................................. 22
Figure 7 Example of Flange Ground...................................................................................................................................... 22
Figure 8 Optional Blocking Devices....................................................................................................................................... 24
Figure 9 954 SmartServo FlexLine Board Overview .............................................................................................................. 29
Figure 10 Intrinsically Safe and Non-Intrinsically Safe Cable Entries.................................................................................... 30
Figure 11 Wiring Connection Descriptions ........................................................................................................................... 31
Figure 12 Topology................................................................................................................................................................ 37

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1. GENERAL
UsingthisInstallationGuide
The 954 SmartServo FlexLine is used in measurement systems for inventory
measurement and control. The 954 SmartServo FlexLine can integrate data from other
measurement devices, such as temperature RTD sensors.
Data from 954 SmartServo FlexLine and connected sensors can be communicated to host
computer systems via a variety of industry standard protocols.
RelatedDocuments
954 SmartServo FlexLine Safety instructionsfor installation, commissioning, operation,
and maintenance; shipped with the device
CE Declaration of Conformity
EC-Type Examination Certificate
IEC-Ex Certificate of Conformity
Control drawings for FM and CSA
Trademarks
HART® is a registered trademark of the HART Communication Foundation.
Contact
Head Office - Delft, The Netherlands
Honeywell Enraf
Delftechpark 39, 2628 XJ Delft
PO Box 812, 2600 AV Delft
The Netherlands
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Website: http://www.honeywell.com/ps

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2. SAFETY AND SECURITY
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.
SafetyConventions
WARNINGS
Thefollowing warning symbol is used in this manualto urgeattention in order to prevent personal
injuriesordangeroussituations,furtherdescribed inthismanual.
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

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SafetyInstructions
2.3.1.SafetyInstructions
See the safety instructions shipped with the device for installation, commissioning,
operation, and maintenance.
2.3.2.ECDeclarationofConformity(forEU)
Refer to the EC declaration of conformity shipped with the device.
2.3.3.ControlDrawingsforFM&CSA
Refer to the control drawings shipped with the device.
2.3.4.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 installationproceduremust be carriedout in accordancewith national, local, and
company regulations.
The entire electrical installation shall be carried out in accordance with the national
requirements for electrical equipment to be installed in hazardous areas.
NOTE:
See EN IEC 60079-14 or NEC (NFPA70).
2.3.5.AdditionalInformation
If you require additional information, contact Honeywell or its representative.
2.3.6.EnvironmentalConditions
Observe the environmental conditions for the temperature and the pressure.
Ambient Operating Temperature Range from -40°C (-40°F) up to +65°C (149°F).

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Liability
The information in this Installation Manual 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 Installation Manual are subject to
change without notice. Honeywell accepts no responsibility for any errors that may appear
in this Installation Manual.
WARNING!
Only certified technicians are authorized to make changes on the 954
SmartServo FlexLine configuration. All modifications must be in accordance to
the guidelines as set forth by Honeywell. Modifications not authorized by
Honeywell will invalidate the approval certificates.
Labels
Figure 1 Identification Label with Safety Note on the 954 SmartServo FlexLine
NOTE:
This is a conceptual view of the type plate and therefore subject to change.

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PersonalSafety
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 vapors are present
(compressed air, chemical protection suit, and detection equipment).
WarningsandCautions
2.7.1.General
Opening of the Instrument
WARNING!
DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE MAY BE PRESENT.
When it is required to open the instrument in an explosive hazardous environment,
take care of the following:
WARNING!
Make sure that the power to the device is switched off before you open the
covers of the device. Failure to do so may cause danger to persons or damage
the equipment. All covers of the device must be closed before switching the
power on again.
WARNING!
Treat the O-ring groove surfaces of the housing with care. Keep the screw
threads of the lids free of dirt. Both O-rings must be present and undamaged.

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Closing of the Instrument
Make sure that the O-rings are placed in the groves on the housing (main compartment
and the terminal block compartment).
Tools
WARNING!
Use non-sparking tools and explosion-proof testers.
Use suitable explosion proof tools (for example, testing devices)!
Working Environment
Hazardous Area
WARNING!
Potential Electrostatic Charging Hazard!
Avoid generation of static electricity.
Safe Area
WARNING!
Avoid generation of static electricity. Make sure noexplosive gas mixtures are build
up in the working area.
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.

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

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CAUTION!
The box in which the 954 SmartServo FlexLine arrives also contains the
measuring drum. This is a precision measuring device and shall only be installed
by a qualified commissioning engineer. Accurate measurement requires an
undamaged and clean drum.
Figure 3 Measuring Drum
Special Tools:
Screw driver for Hex Allen-key screws M4 (length min. 22 mm)
Tommy bar
Accordanceto Regulations
2.9.1.ExplosionSafety
ATEX
II 1/2 G Ex db h IIB T6 Ga/Gb or II 1/2 G Ex db eb h IIB T6 Ga/Gb or II 1/2 G Ex
db h [ia Ga] IIB T6 Ga/Gb or II 1/2 G Ex db eb h [ia Ga] IIB T6 Ga
Certificate no. ATEX: DEKRA 18ATEX0052 X
IP66/67

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IECEx
Ex db h IIB T6 Ga/Gb or Ex db h eb IIB T6 Ga/Gb or Ex db h [ia Ga] IIB T6 Ga/Gb
or Ex db eb h [ia Ga] IIB T6 Ga/Gb
Certificate no. IECEX: IECEx DEK 18.0033 X
IP66/67
FM
XP, Class I, Division 1, Group C,D T6
AIS, Class I, Division 1, Group C,D
Ta = -40°C to +65°C
NEMA 4X
Certificate no.: FM19US0012
CSA
Class I, Division 1, Group C,D
Ex db eb h [ia Ga] IIB T6 Ga/Gb
Ta = -40°C to +65°C
Encl 4
Certificate no.: 70210644

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3. PRINCIPAL OF SERVO MEASUREMENT
PrincipleofMeasurement
Figure 4 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.

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3.1.1.LevelMeasurement
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 a direct consequence of the stepper motor principle. The correct functioning
of the stepper motor is continuously checked. This is achieved by decoding the unique
pattern of an encoder disk mounted on the motor shaft.
3.1.2.InterfacebetweentwoProducts
Measurement of the interface between two products is achieved by sending an interface
command to 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.
3.1.3.RelativeDensity
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.

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4. MECHANICAL INSTALLATION
PreparationforTransportationoftheGauge
CAUTION!
Donot transportthe instrument with the motor unlocked. Refer toFigure2 formotor
locking.
Drum should be transported in original protective box. Drum and displacer shall only be
installed by a qualified commissioning engineer.
ProcessConnection
The 954 SmartServo FlexLine can be ordered with raised face or flat face flange. Select
gasket that is suitable for flange type, maximum pressure and product to be stored. Mount
instrument flange horizontally.
WARNING!
Verify that tank or drum compartment is depressurized before opening the tank
or drum compartment cover of 954 SmartServo FlexLine.
The 954 SmartServo FlexLine can be adapted to various process connection flanges via
adapters/calibration chambers as specified in Appendix B. Verify that maximum working
pressure of adapter/calibration chamber complies with pressure in your tank.
WARNING!
954 SmartServo FlexLine gauge should be mounted as horizontal as possible.
Installation under an angle might influence accuracy of the gauge.
NOTE:
When using 954 SmartServo FlexLine on pressurized tank, it is recommended to install a
suitable valve between tank and 954 SmartServo FlexLine to isolate the instrument from
the process when required.
The valve shall have an opening large enough to feed through the displacer.

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Orientationof954SmartServoFlexLineGaugeonTank
Mount the gauge in one of the following two ways:
Figure 5 Orientation of the Gauge on a Tank (top view)
On a stilling well or guide pole, the orientation of the gauge may be chosen freely.
NOTE:
The weight of the 954 SmartServo FlexLine for:
- medium pressure version is : 16 kg (35 lbs);
- chemical version is : 21 kg (46 lbs);
- high pressure version is : 26 kg (57 lbs).