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Kelvin Khoo

854 ATG Servo Level Gauge

Honeywellenraf.com

854 Series Servo gauge TERMINAL COMP. ELECTRONIC COMPARTMENT

DRUM HOUSING

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Archimedes Principle
(Ark-i'-meed-eez). The basic idea is that the Displacer in a liquid produces an upward force equal to the weight of the displaced product. (Archimedes Principle). Weight = Displacer Weight Buoyancy = Immersed Volume *Liquid Density Apparent Weight = Weight Buoyancy

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How is Archimedes
Archimedes (c.287 - c.212 BC) c.250 Archimedes, Greek scholarly. Archimedes was born in Syracuse on the eastern coast of Sicily and educated in Alexandria in Egypt. He then returned to Syracuse, where he spent most of the rest of his life, devoting his time to research and experimentation in many fields. In mechanics he defined the principle of the lever and is credited with inventing the compound pulley and the hydraulic screw for raising water from a lower to higher level. He is most famous for discovering the law of hydrostatics, sometimes known as 'Archimedes' principle', stating that a body immersed in fluid loses weight equal to the weight of the amount of fluid it displaces. Archimedes is supposed to have made this discovery when stepping into his bath.

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854 Series Servo gauges


Principle of measurement

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854 Series Servo gauges


Modular design

Terminal compartment Drum Housing Electronics

F B W
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XPU SPU Option Power

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Equilibrium Condition
Equilibrium Condition
The weight of the partly immersed displacer balances with the weight programmed to be measured by the Force Transducer (FT).

Liquid Level Moving Downward


FT experience increasing weight Upward force no longer acting on Displacer FT communicate with Servo Controller Servo Controller lower Displacer Servo Controller stop until Apparent weight equals the programmed weight

Liquid Level Moving Upward


Reversed the Moving Downward process

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Equilibrium Condition
Buoyancy Largest = Ascend Force Balance = Hover Weight Largest = Sink

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854 Series Servo gauges


Drum Compartment

O-ring sealing

drum, engraved: - drum circumference - production number - serial number

carbon-PTFE bearings

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854 Series Servo gauges


Measuring specifications Level accuracy Level repeatability Interface accuracy Density accuracy Temperature accuracy < 0.4 mm < 0.1 mm < 2 mm < 3 kg/m3 * < 0.1 C *

* Optional

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854 Series Servo gauges


Available Models (1) Sealing facilities for Weights & Measures Digital Pressure transmitters interface for Honeywell / HART protocol Temperature interface (average & spot) Pressure versions Medium pressure, High pressure Drum compartment material - stainless steel or aluminium Safety approvals FM, CSA, SAA, ATEX

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854 Series Servo gauges


Available Models (2) Measuring range 27 m., 37m., 35m. with 150 m. total wire lenght Wire material SS-316, Hasteloy C22, Tantalum, Invar Mains supply 110/130/220/240 V, optional 65 V Density measurement Alarm contacts (2 * SPDT)

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854 Series Servo gauges


Features and benefits Features
wire weight compensation hydrostatic tank deformation compensation adjustable balance setpoint servo density modular design with optional boards full galvanic isolation programmable via PET and PC

Benefits
smaller level error,smaller displacer diameter improved accuracy without standpipe water interface and product level with one displacer average density and density profiling easy upgradable, low spare parts costs unsurpased lightning protection easy setup, maintenance and repair

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854 Series Servo gauges


Conclusions One instrument for: - Level - (Average) Temperature - Interfaces - Density - Level alarms Easy installation Low cost of ownership Attractive price Easy to upgrade

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Lightning Protection
field side L or R Instrument side field side
Instrument side

GDT

MOV suppression

TZ

Diversion

INCORRECT

CORRECT

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854 ATG
General hardware
terminal compartment

electronic compartment

drum compartment

measuring wire

displacer

854 ATG
Principle block diagram

drum

motor D U

force transducer

weight meas.

motor control

control electr.

apparent weight

854 ATG
Servo hardware
Displacer produces via drum torque on drumshaft Motor unit fixed on drumshaft Motor unit applies force to force transducer Force transducer converts force into frequency
transport lock drum motor unit drum shaft force transducer

SPU (Servo Processing Unit) receives frequency from force transducer and controls displacer position via motor unit

854 ATG
Standard displacers

Weight [DW]
(grams)

223 3 45 16 100 5 Carbon-PTFE 12 2

223 3 90 64 100 5 Carbon-PTFE 31

223 3 110 95 100 5 Carbon-PTFE 2 0.5

Diameter
(mm)

Area [DA]
(cm)

Volume [DV]
(cm)

Material Immersion depth


(at = 0.8 gr/cm) (mm)

depending on application, a range of displacers is available, regarding material, size and construction

854 ATG
Measuring wire
Material standard stainless steel optionally Hasteloy, Tantalum or Invar Typical Wire Weight [WW] 0.25 gr/m diameter 0.2 mm Important: keep wire free of kinks Use lug at wire end to attach displacer Secure and ground displacer New wire on drum apply wire with sufficient tension

854 ATG
Displacer attachment
measuring wire from drum additional piece (approx. 0.5 m) lug displacer

2 or 3 x

5x

854 ATG
Drum
Drum with precise grooves Typical: drum circumference [DC] engraved on drum (0,335...0,340 m) drum error 0.7 mm (calibration report in instrument packing) mechanically balanced ( 5 mg) range 27 m (optionally 37 m or higher) axial travel 27 m 1.5 mm/m 37 m 1.0 mm/m Transport of instrument with drum separated Check drum circumference Check axial freeplay (approx. 2 mm) Keep drum, wire and displacer clean

854 ATG
Magnet coupling
Typical 3 pole-pairs magnet slip at 1 kg magnet slip detection [WT] possible magnet slip coupling correction [CC] & [RM] Isolates tank atmosphere safety pressurized tanks aggressive products Protects weighing balance against..... mechanical shocks and excessive load Magnet cap made of non-magnetic material provided with 2 bearings for full drum support do not remove magnet cap keep outer magnet clean and free of (metal) particles
N S S N S N N S N S N S

854 ATG
Bearings
Made of Carbon-PTFE conductive because of safety (carbon) Periodical maintainance estimated once per 10 years use genuine parts 'special tool' required (drum bearing puller from tool set) Check bearings by moving drum up/down

854 ATG
Force transducer
Converts force (F) into frequency (f) Protect force transducer against mechanical shocks use transport lock during transportation of instrument Caution handle with care do not readjust any settings

854 ATG
Force transducer
Apparent weight [g] 0-300 Output f [kHz] 11-16

Range

force
Each force transducer... has an individual characteristic is 100% factory tested sensitivity 8 Hz/g temp. range -30...+65 C Service [MF] (20 sec) Measure Frequency [WQ] Weight reQuest [FQ] Frequency reQuest

854 ATG
Gauge calibration
F3 F [Hz] F2 F1

F0

[MF] - [FQ] - [WQ] [BT] - [BF] - [BU] - [BW] - [BV]

0 25

100

175

250

S [g]

25

25 75

25

25

150

225

854 ATG
Motor unit (old)
Motor unit fixed to drumshaft and force transducer Motor unit should be free from any other obstacle check when assembling (e.g. after repair) Transportation of instrument always use transport lock Check proper operation of motor unit with command [TG]

transport lock motor unit locked motor unit unlocked

854 ATG
Motor unit (new)
Motor unit fixed to drumshaft and force transducer Motor unit should be free from any other obstacle check when assembling (e.g. after repair) Transportation of instrument always use transport lock Check proper operation of motor unit with command [TG]
motor unit locked motor unit unlocked

854 ATG
Reference encoder
Verifies all movements made by stepper motor Coded disc is moving through photointerruptor, generating bit-pattern Bit-pattern is compared with reference pattern to measure direction and exact number of steps made by stepper motor Missing motorsteps are detected and automatically corrected Number of motorstep correction is counted, [ME] 01
1:34

stepper motor RE

854 ATG
Reference encoder errors
Solve error as per description of error code SPU [ES] Resynchronise reference encoder using 847 PET type in: W2=ENRAF2 (enter password level 2) SM (Set Maintenance) FP (Find Position) SO (Set Operational) EX (EXit from protection level 2) recalibrate level

854 ATG
Gauge accuracy
Display = accurate level level error Level error L depends on gauging platform (e.g. hydrostatic deformation) instrument accuracy tank temperature Instrument accuracy depends on drum instrument sensitivity (weighing balance) wire weight (automatic correction with items [TT] and [WW]) magnet coupling (automatic correction with items [RM] and [CC]) moving parts (can be checked with item [BT])
Instrument accuracy drum sensitivity (i) moving parts TOTAL W&M [mm] 1.4 0.3 0.3 2.0 854 [mm] 0.5 0.1 0.1 1.0

854 ATG
Backplane
Backplane-I or -II mains voltage selector 1st slot: XPU (X-mission Processing Unit) 2nd slot: SPU-I or -II (Servo Processing Unit) 3rd slot: optional board 4th slot: GPS (Gauge Power Supply) All circuit boards are secured via a retaining screw (screwdriver) a locking latch on the XPU Backplane-II fully compatible with backplane-I backplane-II has additional features/options backplane-I will become obselete
mains voltage selector

1st 2nd 3rd 4th

motor unit force transducer

854 ATG
Backplane

infra red mains transformer 110 V 130 V or 65 V 220 V 240 V 240 V

1st slot

2nd slot

3rd slot

4th slot fieldbus mains

854 ATG
XPU-1
locking latch (left = locked) galvanic isolation (fieldbus) NOVRAM RAM jumpers software EPROM view angle adjustment 2x16 LCD display

(safety) ground

854 ATG
XPU-2
locking latch (left = locked)

(safety) ground future expansion

galvanic isolation (fieldbus) software EPROM NOVRAM

2x16 LCD display HALL-switches

jumpers

854 ATG
XPU
PET-link (infra red) NOVRAM EEPROM HOST-link (Bi-Phase Mark) inter processor communication GPS interrupts microprocessor RAM DISPLAY TEST (reed switch) JUMPERS EEPROM NOVRAM 512 bytes 1024 bytes (required for HPU/OPU/HSU option) EEPROM 32 kB (straps 6 & 7 0) 64 kB (straps 6 & 7 1)
default settings (NOVRAM)

RAM

option I option II

XPU-2 only

854 ATG
SPU
(safety) ground 2c for relais R2 2c for relais R1 (relais are optional)

R1

R2

software EPROM

854 ATG
SPU
SPU-1 with / without option for servo density measurement SPU-2 replaces SPU-1 with / without option for alarm relay with / without option for servo density measurement

Software version SPUAn.n SPUBn.n SPUCn.n SPUDn.n

Alarm relay N Y N Y

Servo density N N Y Y

854 ATG
GPS

fuse 250 mA slow fuse 1 A slow

854 ATG
GPS

+16 V +12 V 0V -12 V -16 V +5V 0V

B U F F E R

F1 1 A/T 65 V~

LPW IP-RST SUP-RST GPS control

F2 250 mA/T 12 V~

854 ATG
Safety aspects
Observe local-, company- and certificate requirements Installation in hazardous areas Protection methods explosion proof increased safe intrinsically safe Protective grounding Cable entries 2 x " NPT for non-intrinsic safe cabling 2 x " NPT for intrinsic safe cabling use only approved cable glands or conduits Water ingress protection IP54 Full lightning protection by galvanic isolation Modification of any kind NOT allowed

854 ATG
Safety aspects
Terminal compartment explosion proof or increased safe (only for zone 1)

A A
Electronic compartment explosion proof

Drum compartment

A C

A Threaded flame path B Flat flame path C Cylindrical flame path

grounding TANK

854 ATG
Powering up
GPS MPU SPU XPU sec. POWER ON

10 20 30 40 50 60

GPS: powering up XPU: NOVRAM-data check & distribution start-up SPU: reference encoder test/ servo start-up
Note 1: if display does not show I1, but anything else except FL, check [LC]. Issue commands [UN] and [I1] to go to I1 Note 2: Procedure for start-up after reset [RS] or [EX] differs slightly, see [ER]

10145

854 ATG
Trouble shooting
Nothing on display (while instrument is installed on tank top*) switch mains off and on and observe display check mains voltage level ( 80% ?) power off; open covers and check wiring, connectors check fuse(s) on GPS; replace GPS close covers and switch power on power off; open cover and replace XPU** close cover and switch power on power off; open cover and replace EEPROM on XPU*** close cover and switch power on
* ** *** in safe area (workshop), keep cover open and observe LEDs on circuit boards use spare XPU without EEPROM; use EEPROM from replaced XPU make sure EEPROM is of same version as existing one; if not, replace complete set of EEPROM (XPU, SPU and ?PU) and reformat NOVRAM

854 ATG
Options (SPU)
SPU-I level water level soft alarms option: servo density SPU-II level water level soft alarms options: servo density (density profile) alarm contacts (hard alarms) servo density + alarm contacts

854 ATG
Test weights (part no. 1854.061)

1 85

70

3 110

18

Item 1 2 3 4

Weight [g] 25 75 150 225

18

18

150

854 ATG
Tool set (part no. 1854.062)
06 105 05 85 04 75 03 65 02 50 01 45 07 20 09 53 08

335

10

Item 1 2 3 4 5 6 7 8 9 10 11

Description Socket head screw wrench 2 mm Socket head screw wrench 3 mm Socket head screw wrench 4 mm Socket head screw wrench 5 mm Socket head screw wrench 8 mm Drum bearing puller Test magnet Socket head screwdriver M4 Socket head screwdriver M6 Pipe wrench 27 mm Tommy bar

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