Honeywell 8in1 Gauging Solution for Barges

Introduction

This manual is issued specifically for the Barge system and contains detailed instructions for its functioning and operation. To use the system optimally, it is advised to read these instructions carefully and respect them throughout the life of the equipment. Keep this manual handy for reference, ensuring it is complete and kept close to the equipment.

The system integrates the Alarm Cabinet, OPTILEVEL probe, PL3700 pressure transmitter, and LIDEC level switch for processing liquid cargo on barges and inland vessels. It is intended for professional use by qualified operators familiar with operating rules and safety instructions. Honeywell Marine is not liable for risks arising from connecting equipment or using products not recommended by them. Reproduction of this manual requires prior written approval from Honeywell Marine.

As technology advances, equipment may undergo technical or design changes, potentially altering features and information in this manual without prior notice. Pictures in this document are not contractual. For any problems or questions regarding this Barge system, contact your nearest Honeywell Marine customer service.

Other documents:

• The description and operation of the OPTILEVEL probe and Supply are detailed in the MT5025E technical manual.
• The description and operation of the LIDEC level switch are detailed in the NT406 technical manual.

Safety Precautions:

Personnel responsible for commissioning and operating intrinsically safe equipment must be knowledgeable of and follow current regulations and legislation applicable to hazardous areas. Always switch off the power before disconnecting or removing transmitters.

Warnings and Compliance

Honeywell equipment is designed and manufactured in accordance with local safety regulations and European directives, including:

• 89/336/EEC and 2004/108/EC for Electromagnetic compatibility.
• ATEX 94/9/EC for equipment and protective systems intended for use in potentially explosive atmospheres.
• 96/98/EC for Marine equipment.

The OPTILEVEL HLS 6010 / OPTILEVEL Supply, PL3700 pressure transmitter, LIDEC level switch, and associated transmitters are certified for use in hazardous areas according to intrinsic safety protection types. They are intended for professional use and must be installed, used, and maintained by qualified personnel. Honeywell cannot be held responsible for unauthorized technical alterations or damage resulting from operation outside specified technical classifications (e.g., power supply, temperature, environment).

The safety instructions in this manual are for guidance to protect users. Honeywell Marine cannot foresee all dangerous situations; therefore, the owner and/or operator is responsible for the system's operating safety. Ship classification society regulations may impose stricter procedures (health, safety, fire prevention, handling of hazardous substances) than those in this manual, and must be followed if applicable.

General Description

The system provides a comprehensive solution for cargo control needs on barges and inland vessels, requiring only one 8" hole in the tank for multiple functions. It supports two level alarms, Inert Gas pressure, level, temperature, oil/water interface measurement, manual gauging, and sampling.

System Overview Diagram: The system diagram illustrates the integration of various components. An Alarm/System cabinet is connected to a TA3840S-C display unit or TA3840R remote display unit. A PL3700 Atmospheric pressure transmitter is situated in the 'Safe area'. In the 'Hazardous area', an Optilevel probe and a LIDEC level switch are mounted on a PL3700 I.G. pressure transmitter. The system also includes Orange & Red Lights and Sirens for alarms.

System Description

The system comprises Optilevel probes for level, temperature, and oil/water interface measurement, PL3700 I.G. pressure transmitters for inert gas pressure, a PL3700 Atmospheric pressure transmitter, a LIDEC L92 level switch for High and Overfill alarms, a valve for UTI meter connection (manual sounding/sampling), a cabinet, and Orange/Red Light/Siren indicators, along with a TA3840S-C display (or TA3840R remote display).

Cabinet Contents:

• TA3840S-C control & display unit (optional).
• I/O signals for LIDEC L92B (High and Overfill alarms) with zener barrier.
• Independent alarm central units with alarm sequence for High and Overfill levels.
• Optilevel Supply unit to power Optilevel probes in hazardous areas.
• High and Overfill Light and Siren outputs with zener barrier (relay outputs optional).
• 4-20mA inputs for I.G. pressure transmitters with zener barrier (for hazardous areas).
• 4-20mA input for atmospheric pressure transmitter.
• 4-20mA inputs for Trim / Heel inclinometer (optional).
• 4-20mA inputs for Draft measurements (optional).

8" Flange Support:

• Optilevel probe.
• PL3700 I.G. pressure sensor.
• LIDEC L92 double level switch.
• 2" valve for manual gauging and sampling.

The TA3840S-C control & display unit reads and processes data from Optilevel probes, I.G. pressure transmitters, and the Atmospheric pressure transmitter. This unit is typically housed within the cabinet or on a console, with the TA3840R remote display available as an option.

2.1 Alarm / System cabinet

This cabinet is designed for barges and inland tankers, incorporating two main systems: Cargo Tank measurement (Level, Temperature, I.G. pressure, oil/water interface) and Cargo Tank Alarm (High and Overfill level). The cabinet is powered by 24Vdc from the barge, with a 24Vdc/230Vac converter supplying the entire system.

Cabinet Interior Description: The Alarm/System cabinet interior displays three main electronic boards, labeled 1, 2, and 3. Board 1 is identified as the Optilevel Supply unit, responsible for powering Optilevel probes in hazardous areas. Boards 2 and 3 are main electronic boards that manage the Cargo Tank Alarm (High Level and Overfill) functions, receiving signals from LIDEC Level switches and other inputs.

Cargo Tank System Measurement:

The Optilevel supply (Item 1) powers Optilevel probes from Safe to Hazardous areas (ATEX and IECEx approved), supporting up to 8 probes. Multiple Optilevel supplies can be paralleled for vessels with more tanks. Digital signals from Optilevel probes are converted from RS232 to RS485 on the HLA main board and processed by the TA3840S-C unit. The TA3840S-C can be mounted on the cabinet's front panel or a console. A TA3840R display repeater can be connected to the TA3840S-C if more than one display is needed.

Cargo Tank Alarm (High Level and Overfill):

High Level Alarm (HLA) and Overfill Alarm (OFA) are independent systems. Each main electronic board (Items 2 and 3) is supplied by 230Vac/24Vdc and 230Vac/5Vdc power. Up to 10 LIDEC Level switches can connect to the main board, triggering alarm sequences: 1st alarm activates buzzer, klaxon/light, and low flashing alarm light. Acknowledgement silences the buzzer and klaxon, keeping the alarm light on. Subsequent alarms increase flashing frequency. All alarms turn off when the condition clears. A Loading/Navigation switch inhibits alarms in navigation mode, indicated by a blue light.

2.2 TA3840S-C control & display unit

The TA3840S-C Communication Unit queries digital transmitters (Optilevel probes), receives analog (4-20 mA) and on/off sensor data, displays processed information, transmits data serially, monitors system and data alarms, and manages on/off outputs. It also provides maintenance functions.

TA3840S-C Functions:

• Collects raw measurements from Optilevel probes, analog 4-20 mA transmitters (PL3700 I.G. pressure, PL3700 Atmospheric pressure, Trim/Heel inclinometer, Drafts – all optional), and on/off transmitters (optional).
• Performs measurement scaling and processing.
• Manages communication and data validity, monitoring for "System Fault" alarms.
• Displays final data on an LCD screen.
• Controls final data based on two alarm limits per channel, triggering "data alarm" sequences.
• Transmits data via a serial link (MODBUS RTU protocol) to monitoring systems, loading software, TA3840R remote display units, or other applications.
• Manages on/off outputs.
• Transmits data to the LOG3840 deck indicator (optional).

The TA3840S-C unit is installed in a console with a front panel featuring an LCD screen for data/alarms, status lamps, a function selection keypad, and a numeric keypad for configuration. Its intuitive interface simplifies access to functions and configuration via scrolling menus. For more details, refer to the MT5008E Technical manual.

2.3 Optilevel HLS 6010 probe

The Optilevel HLS 6010 probe consists of a head housing with electronics, a screw thread for tank attachment, and a measuring tube whose length depends on the tank diameter. It is ATEX/IECEx approved (Ex ia IIB T4 Ga/Gb). The probe measures level, temperature, and water at the bottom (0 to 250mm). It is supplied by an ATEX/IECEx approved Optilevel Supply module ([Ex ia Ga]). The OPTILEVEL HLS 6010 probe has Type Approval from major Classification Societies. For more details, refer to the MT5025E Technical manual.

2.4 LIDEC L92 level switch

The LIDEC L92 level switch operates on the principle of absorbing mechanical waves within the probe, detected by a piezoelectric sensing element. The LIDEC detector is Type Approved by major Classification Societies. The LIDEC L92 integrates two independent probes and electronics for marine requirements and is ATEX/IECEx approved (Ex ia IIB T4, T5, T6 Ga). For more details, refer to the MT5003E Technical manual.

2.5 PL3700 pressure transmitter

The PL 3700 series is a 2-wire, 4-20 mA level and pressure transmitter comprising a transducer and amplifier connected via a shielded/vented cable. The submersible (IP68) transducer is housed in stainless steel AISI 316L or composite material (PL3700 C model) with a capacitive Ceramic diaphragm. The amplifier is housed in a sea water-resistant polyester casing (IP 66) or stainless steel casing (IP66/67) and can be installed on deck. The PL 3700 is available with programmable ranges for level and pressure, as absolute or gauge type. Its transducer can be immersed or side-mounted.

2.5.1 PL3700 I.G. pressure transmitter

The PL 3700 I.G. is designed for inert gas pressure measurement, measuring absolute values from 800 mbar to 2000 mbar, compensated by the PL3700 Atmospheric pressure transmitter. Absolute pressure transmitters are used to prevent water ingress from vent pipes. It is ATEX/IECEx approved (Ex ia IIB T6 Ga). For more details, see NT5090E Technical manual.

2.5.2 PL3700 atmospheric pressure transmitter

The PL 3700 Atmo measures atmospheric pressure from 900 mbar to 1100 mbar and compensates the PL3700 I.G. pressure transmitters. It is ATEX/IECEx approved (Ex ia IIB T6 Ga). For more details, see NT5090E Technical manual.

2.6 HERMetic UTImeter (optional)

The HERMetic UTImeter Gtex is a portable, gas-tight liquid level gauge for closed gauging of hydrocarbons and chemicals. It is used for custody transfer, inventory control, and free water detection on barges, marine vessels, and shore tanks. The UTImeter connects to a HERMetic vapour control valve on the 8" flange. It enables measurements of Ullage, Temperature, Oil-Water interface level, and optionally Innage/Reference height (Visc version). It is ATEX approved (II 1 G Ex ia IIB T4). For more details, see Gtex-HM-10-12-ENG datasheet.

2.7 HERMetic Sampler (optional)

The HERMetic Sampler GTX Chem is designed for closed sampling of liquids or chemicals that pose fire, health, or air pollution hazards. Its gas-tight construction prevents pressure release and fume exposure. It is ATEX approved (II 1 G c IIB T6). For more details, see HM-09-08-ENG brochure.

3. Installation / Configuration

3.1 Cabinet

The cabinet (IP52 certified) must be installed in a safe area and protected from weather. LIDEC level switch validation is set by DIP switches (SW1 to SW10) on the main board: SW1 (for LIDEC1) at bottom, SW10 (for LIDEC10) at top. 'On' indicates LIDEC connected, 'Off' indicates not connected.

Cabinet/RS232 Connections Description: The cabinet's main board features DIP switches, specifically SW1 for LIDEC1 and SW10 for LIDEC10, used for validating LIDEC level switches. A separate section shows the RS232 terminal connections, detailing the pins for Supply, RES (Reserve), GND, RxD, and TxD, which are used to connect a laptop for probe configuration via the Comport.

Optilevel probe configuration is done using the Com3840 software. The serial line must connect the computer's Comport to the Optilevel Supply.

3.2 Equipments

Refer to the respective manuals for each equipment:

• OPTILEVEL probe: MT5025E Technical manual.
• LIDEC L92 level switch: NT401 Installation manual.
• PL3700 pressure transmitter: MI5090 Installation manual.
• TA3840S-C display: MI5008E Installation manual and Com3840 commissioning software for data setup.

COM3840 Commissioning Software Description: The COM3840 commissioning software interface is displayed, showing the 'OPTILEVEL page configuration'. Users can input the probe's serial number (S/N), set a new address and product code, and adjust the baud rate. The interface includes fields for 'Level', 'Water', and 'Temperature' measurements, along with an 'Offset' setting. Buttons like 'Write Address/Product', 'Write Baud Rate', 'Write Offset', and 'Read' are available for configuring the Optilevel probes. The software operates at 9600 bauds for configured probes, defaulting to 300 bauds for unconfigured ones.

Optilevel probes operate at 9600 bauds but default to 300 bauds if unconfigured. Use the settings/communication menu to set the correct baud rate. The probe's serial number (S/N) must be entered to configure it with a new address and product code (use '8' for any product). Push "Write Address / Product" to receive a response from the probe. If the baud rate is not 9600, push "Write Baud rate". Set the offset (mm) based on the distance from the bottom to the probe's end, then push "Write Offset". Use the "Read" button to confirm the probe is responding correctly.

4. Maintenance

Refer to the respective manuals for maintenance of each equipment:

• OPTILEVEL probe: MT5025E Technical manual.
• LIDEC L92 level switch: NT401 Maintenance manual.
• PL3700 pressure transmitter: MM5090 Maintenance manual.
• TA3840S-C display: MM5008E Maintenance manual.

5. Communication

A MODBUS RTU RS232 or RS485 serial line is used for data transmission to monitoring software (e.g., CargoBoss software from Honeywell Marine) or loading software. Refer to ST1128 communication protocol.