TYPE TN3801 Technical Manual SAS au Capital de 2 158 244-444 871 933 R.C.S. Bourges - APE : 2651B Headquarter : 9, rue Isaac Newton - 18000 Bourges - France
Technical Manual TYPE TN3801 1 st Edition Released February 2013
INTRODUCTION This manual is issued specifically for the Tank Net 3801 electro pneumatic level measuring system. It contains instructions detailed for functioning and operation of this system. To use it in an optimal way, we advise you TO READ CAREFULLY THESE INSTRUCTIONS and to respect them throughout the life of the equipment. Keep this manual to hand so that you can refer to it at any time. Ensure that it is complete and kept close to the equipment. The TN3801 electro pneumatic level measuring system is dedicated to measure the service tanks and ballast tanks liquid level, as well as drafts. This system is intended for professional use, it must be used by operators who are qualified and well-versed in the operating rules and safety instructions set out in this manual. We also draw your attention to the fact that the connection of equipments or the use of products other than those recommended by Honeywell Marine may present risks for which we will not be liable. This manual must not be reproduced in any form whatsoever without the prior written approval of Honeywell Marine who cannot be held responsible for any use of the information contained in this manual. As we want you to take advantage of the most of the latest technology and new equipment, as well as to benefit from our experience, our equipments may undergo technical or design changes. As a result, some of the features and information in this manual may change without prior notice and without any obligation to up-date it. Pictures of this document are not contractual. Should you encounter any problems or have any questions about your TN3801 system, please do not hesitate to contact your nearest Honeywell Marine customer service. Other documents The installation of TN3801 electro pneumatic system is described in the MI5015E installation manual. The maintenance of TN3801 electro pneumatic system is described in the MM5015E maintenance manual. SAFETY PRECAUTIONS: In order to avoid the electric shock or fire hazards, do not expose the equipments to water projections. Take care to switch the power off before proceeding to any action on the electrical parts. Take care to maintain the main unit distant from all heat sources.
Warning: Our equipments are designed and manufactured in accordance with local safety regulations, and in particular European directives relative to reconciling member states' legislation: 89/336/EEC and 2004/108/EC "Electromagnetic compatibility", 96/98/EC "Marine equipment". They are intended for professional use and must be installed, used and maintained by competent staff that are qualified in this type of equipment. In particular we wish to draw your attention to the fact that we cannot be held responsible if: Any technical alterations are made to our appliances without our written authorisation, Our equipments are damaged by being operated in conditions other than the intended usage of their technical classification (power supply, temperature, environment, etc.). The safety instructions given in this manual are merely given for guidance purposes to protect you and all those using and working on our equipments. Honeywell Marine cannot foresee all dangerous situations that might arise. This is why the owner and/or the operator is responsible for the operating safety of the system. Regulations of the ship classification society may impose procedures (health and safety, fire prevention, handling of hazardous substances, etc.) which are stricter than those given in this manual. In this case, the regulations must be followed. Regulation marking Manufacturer's name and address Serial number Manufacturing month and year EC marking
Cleaning PERMANENTLY MAINTAIN THE SYSTEM CLEAN. BEFORE CLEANING, POWER THE SYSTEM OFF. The use of highly corrosive products is to be proscribed for the cleaning of our equipments, as well as washing with the water hose and the high-pressure cleaner. Avoid projections during the floor washing around the system. The front face of the display unit must be cleaned if necessary with a cloth soaked with soapy water, whereas the functional components must be cleaned using a soft and dry cloth.
TABLE OF CONTENTS 1. GENERAL DESCRIPTION... 7 System description... 8 Main unit... 8 Processing / display unit (optional)... 10 Module for 4-20 ma analog inputs collection (optional)... 11 Module for 4-20 ma output per channel (optional)... 11 2.TECHNICAL SPECIFICATIONS... 12 Basic electro pneumatic system... 12 Processing / display unit (optional)... 12 Module for 4-20 ma analog inputs collection (optional)... 12 Module for 4-20 ma analog output per channel (optional)... 12 3.OPTIONAL PROCESSING / DISPLAY UNIT... 13 Starting up... 13 Functioning modes... 13 LCD display arrangement... 13 Keypads... 14 Display... 15 Main menu functions... 16 Data alarms... 23 System alarms... 24
1. GENERAL DESCRIPTION TN3801 electro pneumatic system RS422 or RS485 (redundant) To the monitoring system - Modbus protocol or RS485 To the TA3840C - EMS protocol or RS485 To the display unit (built-in or remote) Bubbling lines (optional) Air or neutral gas supply 4-20 ma outputs (optional) To the monitoring system - Modbus protocol 115 / 230 Vac 50 / 60 Hz power supply Up to 48 4-20 ma inputs (optional board) Safe area Hazardous area Ballast or service tanks TN3801 Technical Manual 7
System description The TN3801 system is designed for measuring the level of all types of liquid products in a batch of tanks onboard all kind of vessels, ballast tanks, service tanks as well as drafts. The principle is based on the generation of a continuous air or gas-flow bubbling through a pipe running till the bottom of the tank. The pressure of this flow is measured as the hydrostatic pressure due to the liquid column in the tank. This measurement is transmitted by digital redundant lines towards a monitoring system. The TN3801 system includes a main unit, its several options, bubbling pipes,... The main unit gathers the electronic and pneumatic components in a wall-mounted cabinet, made of steel with epoxy painting. The optional processing / display unit questions successively the digital transmitters of the main unit, receives the measurements from the 4-20 ma analog transmitters (if optional module is present) and displays the processed data. The optional 48 analog inputs module collects the 4-20 ma signals from other analog transmitters. The optional 4-20 ma output modules copies the output of a relevant channel as 4-20 ma signal. General synopsis The general synopsis of the system is shown on the previous page. Main unit The main unit is located above the main deck in safe and protected area, such as the control room. This unit hosts : Up to 24 pneumatic bubbling flow modulators, one per channel, each with two manual valves for bubbling fluid supply shut off and bubbling line purge, Up to 3 electronic board including 8 pressure sensors each (2100 or 4000 mbar models), and one microprocessor carrying out the data processing, the digital conversion and the management of two RS422 / RS485 digital communication lines, for redundancy according to Modbus or EMS protocols, One optional 4-20 ma output module per channel A filter-pressure reducer unit for air or neutral gas supply of the pneumatic modulators is located inside this main unit. The pneumatic inlet and outlets are fitted with quick-release couplings. TN3801 Technical Manual 8
Main unit 2 3 4 1 5 1 1 3 2 4 1 1 9 8 7 6 (23 channel model, without any option) 1 Epoxy painted steel cabinet 2 Channel pneumatical modulator 3 Air or neutral gas supply shut off valve 4 Bubbling line purge valve 5 8 channels electronic board 6 Terminal block RS422 / RS485 7 Electrical supply input and digital line outputs (port 1 and 2) 8 Power supply (115 / 230 Vac) 9 Air or neutral gas supply filter / pressure reducer group 10 Pneumatic outlet couplings 11 Black pipes for bubbling lines 12 Red pipes for air or neutral gas supply 13 Blue pipes (hydrostatic pressure) TN3801 Technical Manual 9
Processing / display unit (optional) This unit can be installed on the cabinet door, or in remote box. The TN3801 processing / display unit performs the following functions: collection of the measurements from the transmitters, scaling and processing each transmitter measurements, communication and data validity control, monitoring a "System Fault" alarm sequence, with buzzer and dry contact outputs, final data display on a LCD screen, final data control by two alarm limits per channel monitoring a "data alarm" sequence, data transmission on one serial link toward a monitoring system. The communication uses the MODBUS RTU protocol. The front panel includes: a LCD screen for data and alarms display, status lamps, a keypad menu for function selection, a numeric keypad for configuration and maintenance parameters key in. The use of the keypads is intuitive and does not require a specific training. The large LCD screen increases the data availability and the man-machine interface is simplified for easy access to functions and configuration using scrolling menus. Front face 1 2 3 6 5 4 1 LCD display 2 System fault indicator 3 Power supply indicator 4 Communication port with the electro pneumatic system indicator 5 Numeric keypad 6 Menu keypad TN3801 Technical Manual 10
Module for 4-20 ma analog inputs collection (optional) This option is achieved by addition in the cabinet of a multichannel 4-20 ma input board. It collects the measurements coming from the local analog 4-20 ma transmitters (level measurements, pressure temperature measurements, inclinometers and else). These measurements are transmitted by the same line than the electro pneumatic system board(s). 4-20 ma analog inputs board Module for 4-20 ma output per channel (optional) This option is achieved by addition close to each pneumatic modulator, of a conditioner board for 4-20 ma output. It includes a pressure sensor connected on the pressure output of the pneumatic modulator. 4-20 ma analog output board, for each channel TN3801 Technical Manual 11
2. TECHNICAL SPECIFICATIONS Basic electro pneumatic system Number of channels according to order Bubbling outlet connections coupling for copper or stainless steel pipe dia. 1/4" GAS Pressure sensors range 2100 or 4000 mbar Accuracy 0.3 % range Output Digital format equivalent 12 bits, range 226 to 3850 Temperature drift between 0 and +70 C 0.025% / C Data saving non-volatile memory Communication 2 RS422/485 ports for redundancy, Modbus RTU or EMS protocol, baud rate 1200, 2400, 4800, 9600, 19200, Modbus protocol acc. to doc ST1182 Air or neutral gas supply 5 bar maxi, coupling for copper or stainless steel pipe dia. 1/4" GAS Air or neutral gas consumption 10 l/h per channel at the hydrostatic pressure Main power supply 115 / 230 Vac Power consumption less than 0.5 VA per channel Operating and storage temperature +5 C to +70 C Protection class IP44 minimum Dimensions 1200 x 600 x 300 mm (H x W x D) Weight 90 kg maxi (depending on the channel number and options) Processing / display unit (optional) LCD screen LED indicators on front face Indication of operating faults (data alarms and system faults) 16 lines, 40 columns, back-lighted green for 5 Vdc internal power supply yellow for Tx / Rx communication status with the transmitters red for system faults via buzzer and dry contact output (COM, NO, NC, contact rating 250 Vac / 1250 VA) Communication with upper systems 1 port RS232 / RS485 baudrate 1200 to 19200 Power supply 18 to 36 Vdc, from the TN3801 electro pneumatic system Power consumption 5 VA Dimensions of wall mounting box 420 x 200 x 88 mm (L x W x D) Dimensions of flush mounting type 320 x 132.5 x 60 mm (L x W x D) Module for 4-20 ma analog inputs collection (optional) Number of channels 48 Accuracy of data transmission 0.15 % Connections screw terminals capacity 2.5 mm 2 Transmitters power supply 24 Vdc by internal power supply Communication 2 RS485 ports, Modbus RTU or EMS protocol, baud rate 1200, 2400, 4800, 9600, 19200 Power supply 5 Vdc by internal power supply Module for 4-20 ma analog output per channel (optional) Accuracy 0.3 % Connections screw terminals capacity 2.5 mm 2 Transmitters power supply 24 Vdc by internal power supply TN3801 Technical Manual 12
3. OPTIONAL PROCESSING / DISPLAY UNIT Starting up This unit is powered as soon as the electro pneumatic system is on: - The 5 Vdc indicator (A) lights on, - The starting sequence with display of the name of the vessel as well as the software version appears during a few seconds, then the first page of the main screen is displayed on the LCD display. Check that the Rx/Tx "Sensors port" indicators (B) flash, for due communication with the TN3801 electro pneumatic system. Functioning modes The system can be used according to two functioning modes. NORMAL mode for: Display of final data (for each pressure sensor, transmitter and measurement), data alarms and system faults, Key-in the operating conditions parameters. MAINTENANCE mode for: Display of raw measurements (for each pressure sensor, transmitter and measurement), Display of the alarms historic. The maintenance mode is described in the MM5015E maintenance manual. LCD display arrangement The screen backlight lights on for 30 seconds when pushing any key, or when an alarm occurs until acknowledged. The screen shows the operating conditions, the data, the alarm messages and the functions menu. TN3801 Technical Manual 13
1 2 3 4 5 6 7 8 Each page comprises 16 lines for display and 40 columns. 8 lines are reserved for the data. Keypads LINE 1 LINE 2 LINE 3 LINE 4 LINE 5 LINES 6 to 13 LINE 14 LINE 15 LINE 16 Current date - Time Operating conditions Name of the page - Operating conditions Title of the columns (transmitter name, available datas) Measurements units Lines available for measurements display Message line Dialog line (questions / key-in) Menu line The menu keypad comprises six function keys (F1 to F6). Each key corresponds to the function displayed directly above. The assignment of the keys is different from one menu to another (refer to the paragraphs which describe the menus). The numeric keypad allows to key-in the numerical values in certain menus. It comprises 13 keys: to Numeric keys. Minus sign key. Key to cancel the last keyed-in or displayed digit. [ENTER] key. Validation of the keyed-in value or selection of the current option. This key appears in this manual under the symbol. TN3801 Technical Manual 14
Display After switching on the system, the screen shows the first page of the normal mode, with the main menu. It comprises 15 pages which scroll by successive pushing on the keys UP or DOWN. These pages are gathered by types of measurements. UP DOWN Cargo tanks: PAGE 01 Misc. tanks: PAGE 02 Level, pressure and temperature measurements by radar transmitter Ballast tanks: PAGE 03 Service tanks: PAGE 04 Misc. tanks: PAGE 05 Level measurements by hydrostatic transmitter Inert Gas pressure: PAGE 06 Vapour pressure: PAGE 07 Low pressure measurements Misc. pressure: PAGE 08 Manifold pressure: PAGE 09 Pump pressure: PAGE 10 High pressure measurements Misc. pressure: PAGE 11 Service tanks temp: PAGE 12 Cargo heaters: PAGE 13 Pump temperature: PAGE 14 Temperature measurements Misc. temperature: PAGE 15 Drafts: PAGE 16 Inclinometer: PAGE 17 Drafts measurements Inclinometer measurements Gas concentration: PAGE 18 Gas rate: PAGE 19 Gas concentration TN3801 Technical Manual 15
Main menu functions Following functions are available from the main menu. UP DOWN ACK UTIL SPGR ALRM Go to previous page Go to following page Alarm ACKNOWLEDGEMENT key (1 push for each alarm) Access to UTILITIES menu Access to SPECIFIC GRAVITY menu Access to ALARM menu Main menu UTILITIES menu SPECIFIC GRAVITY and ALARM menus TEST DFT DATE MODE RTN Display, indicators, buzzer and relays test Configuration of default values Setting date and hour Change of functioning mode Return to the upper menu ALL Select all the transmitters of the current page to apply a same value to them PREV NEXT Go to previous transmitter of the current page Go to following transmitter of the current page RTN Cancellation of current action and return to previous display or upper menu TN3801 Technical Manual 16
NOTES: The function keys of certain sub-menus are for transmitter or option selection shown in this document by the following symbols. æ PREV NEXT Reminding: [ENTER] key of the numeric keypad appears in this manual under the symbol. Pushing a forbidden key causes a short beep from the buzzer (if activated). UTILITIES menu TEST The TEST function activates during three seconds all the pixels of the screen, lights on the "System fault" indicator and activates the buzzer and the relay. The return to the current page is done automatically. DFT The DEFAULT menu allows to enter the parameters used for measurements processing. Push DFT to access to the sub-menu and to activate the choice list. Two options are proposed, successively for each parameter: - Use of the value measured by a transmitter (auto). Push [ENTER] to go to the following parameter, - Use of a manually keyed-in value (manu). Push [ENTER] to activate the key-in line. After key-in, validate by pushing [ENTER] to go to the following parameter. TN3801 Technical Manual 17
PREV NEXT RTN Go to previous proposed option Go to following proposed option Cancellation of the current action Atmo. pressure auto? æ Atmo. pressure manu? Atmo. pressure? 1/10 mbar [0-11000]=XXXXX Value measured by the transmitter of the atmospheric pressure OR Manual key-in of the atmospheric pressure value in 1/10 mbar Enter a value between the suggested limits. Trim auto inclinometer? æ Trim auto drafts? æ Trim manu? Value of the trim measured by the inclinometer OR Value of the trim calculated from the drafts OR Manual key-in of the trim value in cm Trim? cm [-+9999]=XXXXX Enter a value between the suggested limits. Heel auto inclinometer? Value of the heel measured by the inclinometer æ OR Heel auto drafts? Value of the heel calculated from the drafts æ OR Heel manu? Manual key-in of the heel value in 1/100 Heel? 1/100 [-+1000]=XXXXX Enter a value between the suggested limits. Trim ref. on perpendicular? æ Trim ref. on shellmark? Processing reference on perpendiculars Processing reference on graduated scales Back to the UTIL menu TN3801 Technical Manual 18
DATE The DATE function allows to enter successively the year, month, day, hour, minutes and seconds. MODE Push DATE to activate the key-in line. After key-in, validate by pushing [ENTER] to go to the following parameter. At the end, the system asks "Exit / Save?" Yes [1] or No [2]. [1] Save and return to the UTIL menu. [2] Cancellation of the keyed-in values and go back to the first question. In this case, pushing RTN allows to return to the UTIL menu. The MODE menu allows to select the buzzer status and the functioning mode. Push MODE to access to the sub-menu which propose two functions. BUZ The BUZZER function allows to enable or to disable the audible alarm. Pushing once on the key allows to go from one option to the other. A message shows the selected mode and the buzzer is activated one shot when enabled. The validation and the return to the MODE menu is automatic after 5 seconds. MNT Selection of the MAINTENANCE mode (requires a password). This mode is described in the MM5015E maintenance manual. RTN The RETURN function allows to return to the upper menu. SPECIFIC GRAVITY menu The SPECIFIC GRAVITY menu allows to key-in the specific gravity of the products relative to the transmitters listed on the current page. This menu is only available from pages 3 to 5, and 16. Push SPGR to access to the sub-menu and activate the message and the key-in lines. Two intervention modes are proposed: - Apply the keyed-in value to all the transmitters of the current page by pushing ALL, - Apply the keyed-in value to a transmitter in particular by selecting it with PREV or NEXT. ALL Push ALL. The following message and the key-in lines are displayed. TN3801 Technical Manual 19
All tanks SpGr? hg/m3 [0-99999]=XXXXX Enter a value between the suggested limits. Back to the main menu The new value is applied to all the lines of the current page. PREV and NEXT The message line shows the name of the transmitter concerning the key-in line (automatically, the first of the list). Tank name : X SpGr? hg/m3 [0-99999]=XXXXX æ Tank name : X+1 SpGr? hg/m3 [0-99999]=XXXXX Push PREV to go to previous transmitter and NEXT to go to following transmitter. After selection of the desired transmitter, enter a value between the suggested limits. Tank name : X+2 SpGr? hg/m3 [0-99999]=XXXXX æ Tank name : X+n SpGr? hg/m3 [0-99999]=XXXXX The new value is displayed on the relevant line and the system proposes the following transmitter. Go to following or previous transmitter, or enter a new value for the current tank. After key-in of the last transmitter value, pushing [ENTER] allows to return to the main menu. Back to the main menu ALARM menu The ALARM menu allows to enter two alarm limits per transmitter listed on the current page and for each possible associated measurements. The limit types are classified by code: 0 = no alarm whatever the limit values, 1 = two high alarm limits (alarm HH/pre-alarm H) ; normal situation below the two limits, 2 = one high alarm and one low alarm (H/L) ; normal situation between the two limits, 3 = two low alarm limits (pre-alarm L/ alarm LL) ; normal situation above the two limits. Push ALRM to access to the sub-menu and activate the message and the key-in lines. The message line shows the name of the transmitter concerning the key-in line (automatically, the first of the list). According to the current page, the key-in line indicates the type of measurement concerned (level, temperature, pressure, and angle). TN3801 Technical Manual 20
Level type:(0),hh/h(1),h/l(2),l/ll(3)= Temp. type:(0),hh/h(1),h/l(2),l/ll(3)= P. type:(0),hh/h(1),h/l(2),l/ll(3)= Angle type:(0),hh/h(1),h/l(2),l/ll(3)= In the following paragraphs, the level measurement is used for example. For the other types of measurements, the method is the same. Two intervention modes are proposed: - Apply the alarm limits to all the transmitters of the current page by pushing ALL, - Enter the alarm limits for a transmitter in particular by selecting it with PREV or NEXT. ALL Push ALL. The following message and the key-in lines are displayed. All tanks Level type:(0),hh/h(1),h/l(2),l/ll(3)= Enter the alarm type code for all the transmitters. Two cases are proposed. Key-in the "0" code All tanks Level type:(0),hh/h(1),h/l(2),l/ll(3)=0 Enter the "0" type code. No alarm limit is applied to the transmitters. Back to the main menu. Key-in the "1", "2" or "3" code TN3801 Technical Manual 21
All tanks Level type:(0),hh/h(1),h/l(2),l/ll(3)=3 Enter the alarm type code. For example "3". All tanks Level LL [0 to 10005 mm]=xxxxx Enter the value for the lowest alarm. All tanks Level L[0 to 10005 mm]=xxxxx Enter the value for the least low alarm. The alarm limits are applied to all the transmitters. Back to the main menu. PREV and NEXT Tank name : X Level type:(0),hh/h(1),h/l(2),l/ll(3)=- æ Tank name : X+1 Level type:(0),hh/h(1),h/l(2),l/ll(3)=- Push PREV to go to previous transmitter and NEXT to go to following transmitter. After selection of the desired transmitter, enter the alarm type code for this transmitter. Two cases are proposed. Key-in the "0" code Tank name : X Level type:(0),hh/h(1),h/l(2),l/ll(3)=0 The following transmitter is displayed. Enter the "0" type code. No alarm limit is applied to the transmitter. Continue the method or go back to the main menu (in the case of the last transmitter). TN3801 Technical Manual 22
Key-in the "1", "2" or"3" code Tank name : X Level type:(0),hh/h(1),h/l(2),l/ll(3)=3 Enter the alarm type code. For example "3". Tank name : X Level LL [0 to 10005 mm]=xxxxx Enter the value for the lowest alarm. Tank name : X Level L[0 to 10005 mm]=xxxxx Enter the value for the least low alarm. Data alarms The alarm limits are applied to the corresponding transmitter. The following transmitter is displayed. Continue the method or go back to the main menu (in the case of the last transmitter). A data alarm starts when a measurement coming from the transmitters exceeds the configured limits. Data alarm typical sequence: The screen backlight lights on, The buzzer is activated in continuous mode, if set enabled, The page number concerned by the alarm appears on the message line, The value out of limits flashes on the relevant page, The relay is activated. Example of display Data in alarm, flashing Page numbers of the value in alarm TN3801 Technical Manual 23
Procedure of a data alarm acknowledgement: Go to the concerned page in order to look at the measurement out of limit flashing. Push ACK (acknowledgement key). The buzzer, if set enabled, passes from the continuous mode to the discontinuous mode (during 2 seconds each 15 seconds), except if another unacknowledged data alarm is present. In this case, it is necessary to acknowledge all the measurements out of limits, one by one. Search and solve the problem relative to the alarm condition. The alarm indication disappears as soon as the cause disappears, depending if the alarm is duly acknowledged. System alarms A monitoring is performed by the system in order to search for intrinsic failures. In the event of default, it starts a system alarm. System alarm typical sequence: The screen backlight lights on, The buzzer is activated in continuous mode, if set enabled, The LED "System fault" lights on, The page number concerned by the alarm appears on the message line, Display of a message alternating with the last valid value on the line of the relevant transmitter, The relay is activated. Procedure of a system alarm acknowledgement: Go to the concerned page in order to read the message on the line of the relevant transmitter. Push ACK (acknowledgement key). The buzzer, if set enabled, passes from the continuous mode to the discontinuous mode (during 2 seconds each 15 seconds), except if another unacknowledged system alarm is present. In this case, it is necessary to acknowledge all the system faults, one by one. Search and solve the problem relative to the alarm condition. When the problem is solved, the alarm condition disappears if this alarm were acknowledged (except if the acknowledgement were disabled during the installation). Communication fault A fault appears when the communication between the processing / display unit and the TN3801 electro pneumatic system is broken. The message "Communication fault" is displayed on the relevant page. Validity fault of the analog measurements A measurement validity fault appears when the signal delivered by the transmitter goes out the nominal rating. The message "Fail" is displayed on the relevant transmitter line. TN3801 Technical Manual 24
Honeywell Marine SAS 9, Rue Isaac Newton 18000 Bourges France Tel + 33 (0) 2 48 23 79 01 Fax + 33 (0) 2 48 23 79 03 E-mail: contact.marine@honeywell.com www.honeywellprocess.com MT5015E-rev06-ENG February 2013 2013 Honeywell International Inc.