Installation Guide

990 SmartRadar 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: HFS-TAC-Support@Honeywell.com
Website: www.honeywellprocess.com

Part Number: 4417760-D10 Installation Guide 2

990 SmartRadar FlexLine
 Contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1 Using this Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.2 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .6
1.3 Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 6
1.4 Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .6

2 Safety And Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . .7

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . 7
2.2 Safety Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . 7
2.2.1 Warnings . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . .. . . .. . . . 7
2.2.2 Cautions . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . .7
2.3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . 7
2.3.1 Safety Instructions . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . 7
2.3.2 EC Declaration of Conformity (for EU) . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . .7
2.3.3 Control Drawings for FM & CSA . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . 7
2.3.4 Users . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .8
2.3.5 Additional Information . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . 8
2.3.6 Environmental Conditions . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . 8
2.4 Liability . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . 8
2.5 Labels . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 9
2.6 Personal Safety . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . 10
2.7 Warnings and Cautions . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . 10
2.7.1 General . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . 10
2.7.2 Tools . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . .10
2.7.3 Working Environment . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . 11
2.7.3.1 Hazardous Zone . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . .11
2.7.3.2 Safe Zone . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . 11
2.7.4 Required Skills . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . 11
2.8 Electrical . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 11
2.8.1 Commissioning and Maintenance . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . .11
2.8.2 Grounding . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . .12
2.9 Accordance to Regulations . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . ..12
2.9.1 Explosion Safety . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . 12
2.10 Compliance to FCC, R&TTE, IC . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . .13
2.10.1 EN 302372-1, ANNEX B . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . 14

3 Product Description . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . 15
3.1 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2 9 9 0 SmartRadar FlexLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.3 HART SmartView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Part Number: 4417760-D10 Installation Guide 3

990 SmartRadar FlexLine
 3.4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.2 Hazardous Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3.1 Storage of Uninstalled Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.3.2 Storage of Installed Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
4.4 Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6.1 Connect 990 SmartRadar FlexLine to Tank Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6.2 Mount Communication Antenna (OneWireless option only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Preparations for Installation with SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.7.1 Open Cover of SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.8 Preparations for Installation without SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.8.1 Remove Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.8.2 Open the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.9 Installing the Cable Glands and Stopping Plugs with SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.9.1 Cable Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.9.2 Unused Cable Inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.10 Installing the Compound Glands, Conduits, and Stopping Plugs without SmartConn . . . . . . . . 27
4.10.1 Compound Glands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.10.2 Conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.10.3 Unused Cable Inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.11 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8
4.11.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.11.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.11.2.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.11.2.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.11.2.3 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.11.2.4 General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.3 Non-intrinsically Safe Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.3.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11.3.2 Enraf Fieldbus (BiPhase Mark) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.3.2.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.3.3 Emerson TRL/2 Field Bus (CAN-TRL2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.11.3.4 Host Communication EIA 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.11.3.4.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.11.3.5 Host Communication EIA 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.11.3.5.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.11.3.6 Hardware Relay Outputs (FII-DO or FII-ALM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Part Number: 4417760-D10 Installation Guide 4

990 SmartRadar FlexLine
 4.11.3.6.1 FII-DO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.3.6.2 FII-ALM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 35
4.11.3.7 HCI-HAO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.11.3.8 SIL Overfill and Underfill Protection (CAN-SIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.11.4 Intrinsically Safe Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.11.4.1 VITO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.11.4.1.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.4.2 HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.4.2.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.11.4.3 FII-RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.11.4.3.1 RTD, 4-Wire Connection (Board ID = 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.11.4.3.2 RTD, 3-Wire Connection (Board ID = 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.11.4.3.3 MPT - MRT (Board ID = 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.11.4.4 Stand-alone SmartView Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.11.4.5 Stand-alone HART SmartView Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.11.4.5.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.11.4.6 RMA805 Enraf FlexLine Remote Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.11.4.6.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.12 Finishing Installation with SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.13 Finishing Installation without SmartConn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.13.1 Close the Cover of the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
4.13.2 Replace the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.14 TRL/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.14.1 Specification TRL/2 990 SmartRadar FlexLine Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.14.2 Electrical Specifications - CAN TRL/2 PWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.14.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.14.3.1 Gauge Scan Issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.14.3.2 TII-XR card Detection Issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.14.3.3 HCI-TRL/2 Detection Issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.14.3.4 SmartLink Scan Issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.14.3.5 Gauge Scan after NOVRAM Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Weight and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Part Number: 4417760-D10 Installation Guide 5

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 1 GENERAL

1.1 Using this Installation Guide

For use in measurement systems for inventory measurement and control. The 990
SmartRadar FlexLine can integrate data from other measurement devices, such as
temperature RTD sensors.

Data from Radar and connected sensors can be communicated to host computer systems
via a variety of industry standard protocols.

1.2 Related Documents

 990 SmartRadar FlexLine Safety instructions for installation, commissioning, operation, and
maintenance; shipped with the device
 Installation Guide 990 SmartRadar FlexLine Antennas
 990 CE Declaration of Conformity
 EC-Type Examination Certificate
 IEC-Ex Certificate of Conformity
 FCC Authorization
 Control drawings for FM and CSA

1.3 Trademarks

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

1.4 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: HFS-TAC-Support@Honeywell.com
Website: www.honeywellprocess.com

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 2 SAFETY AND SECURITY

2.1 General
The 990 SmartRadar FlexLine is a radar-based level gauge to be used in inventory
measurement systems. It can also be used to interface with other systems and sensors such
as temperature gauges.
For the correct and safe installing of this product, it is essential that all personnel follow
generally accepted safety procedures in addition to the safety precautions specified in this
document.

2.2 Safety Conventions

2.2.1 Warnings
Following warning mark is used within this document to urge attention in order to prevent
personal injuries or dangerous situations, further described within this document.

Symbol Description Remark

General warning Will always be explained by text.

2.2.2 Cautions
Following caution mark is used within this document to urge attention in order to prevent
damages to the equipment further described within this document.

Symbol Description Remark

General caution sign Will always be explained by text.

2.3 Safety Instructions

2.3.1 Safety Instructions

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

2.3.2 EC Declaration of Conformity (for EU)

See the EC declaration of conformity shipped with the device.

2.3.3 Control Drawings for FM & CSA

See the control drawings shipped with the device.

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 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 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.

NOTE:
See EN IEC 60079-14 or NEC (NFPA70).

2.3.5 Additional Information

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

2.3.6 Environmental Conditions

Observe the environmental conditions for the temperature and the pressure. See Chapter 5 -
Technical Data.

2.4 Liability
The information in this installation guide is the copyright property of Honeywell Enraf, The
Netherlands.
Honeywell Enraf 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 Guide are subject to change
without notice. Honeywell Enraf accepts no responsibility for any errors that may appear in
this Installation Guide.

WARNING!
Only certified technicians are authorized to make changes on the 990 SmartRadar FlexLine
configuration. All modifications must be in accordance to the guidelines as set forth by Honeywell
Enraf. Modifications not authorized by Honeywell Enraf will invalidate the approval certificates.

Part Number: 4417760-D10 Installation Guide 8

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 2.5 Labels

FIG. 2-1 Identification label (example)

Part Number: 4417760-D10 Installation Guide 9

990 SmartRadar FlexLine
 2.6 Personal Safety

WARNING!
In hazardous areas it is compulsory to use personal protection and safety gear. This can be:
• safety helmet
• fire-resistive overall
• safety shoes
• safety glasses
• working gloves
• LEL-meter

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 necessary precautions.

WARNING!
Take appropriate precautions when chemical or toxic product vapors are present (compressed air,
chemical protection suit, detection equipment).

NOTE:
The emitted microwave energy is far below the accepted limits for exposure to the human body. The
antenna generates a maximum radiation of 0.1 mW/cm2.

2.7 Warnings and Cautions

2.7.1 General

WARNING!
Make sure all 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.

2.7.2 Tools

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.

WARNING!
Use non-sparking tools and explosion-proof testers. Use suitable explosion-proof tools (e.g. testing
devices)!

WARNING!
When it is required to clean the Hart SmartView front panel or the external identification labels
please us a damp cloth with water or a mild detergent only.

Part Number: 4417760-D10 Installation Guide 10

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 2.7.3 Working Environment

2.7.3.1 Hazardous Zone

WARNING!
POTENTIAL ELECTROSTATIC CHARGING HAZARD

• Avoid generation of static electricity.

• In case a wireless 990 SmartRadar FlexLine is installed, do NOT wipe the surface of the antenna
with dry cloth, and do NOT clean its surface with a solvent.

If electrostatically charged, discharge of the antenna surface to a person or a tool could ignite a
surrounding hazardous atmosphere.

2.7.3.2 Safe Zone

WARNING!
Make sure that no explosive gas mixtures build up in the working area.

2.7.4 Required Skills

WARNING!
The technician must have technical skills to be able to safely install the equipment. The technician
also must be trained to work in accordance with the national requirements for electrical equipment in
hazardous areas.

2.8 Electrical

WARNING!
All secondary I/O shall be reinforced or double isolated from mains.

2.8.1 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
paragraph 4.9 and 4.10 to make sure that the correct thread type is selected.
For installations using cable glands, use Ex d compound barrier glands (in case of use
with the SmartConn integrated junction box, see below instead).
Use increased safety (Ex e) cable glands in case a SmartConn box is used.
For installations using conduits, each conduit must be sealed within 18 inches of the
enclosure.
 Improper installation of cable glands, conduits or stopping plugs invalidates the Ex
approval of this device.
 Make sure that the housing of the device is properly bonded to the Protective Earth (PE).

Part Number: 4417760-D10 Installation Guide 11

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 

 The temperature of the device separator coupling (item A in 4.6.1) due to local heat
sources (e.g. contents of a tank as well as power dissipation) may not exceed a
temperature of 80 °C (176 °F).
 Cables and cable glands for at least 80 °C (176 °F) shall be used, unless ambient
temperature is known to be always less than 50 °C (122 °F).


2.8.2 Grounding

WARNING!
When measuring the ground resistance, use a suitable instrument that is approved for use in
hazardous areas.

WARNING!
Safety depends on proper grounding. Check the resistance of the ground connection directly after
installation. The measured ground resistance must be below the maximum prescribed by local and/or
national grounding requirements.

2.9 Accordance to Regulations

2.9.1 Explosion Safety

 ATEX
• 990 SmartRadar FlexLine with Integrated (HART)
SmartView
II 1/2 G Ex d [ia Ga] IIB T4 Ga/Gb according to KEMA 07ATEX0010 X including
Integrated SmartView according to KEMA 07ATEX0011 or HART SmartView according
to DEKRA 16ATEX0103
• 990 SmartRadar FlexLine without Integrated (HART)
SmartView
II 1/2 G Ex d IIB T6 Ga/Gb or Ex d [ia Ga] IIB T6 Ga/Gb according to KEMA
07ATEX0010 X
• SmartConn
II 2 G Ex e [ia Ga] IIB T6 Gb according to KEMA 07AT- EX0093

 IECEx
• 990 SmartRadar FlexLine with Integrated (HART)
SmartView
Ex d [ia Ga] IIB T4 Ga/Gb according to IECEx KEM 07.0003X including Integrated
SmartView according to IECEx KEM 07.0004 or HART SmartView according to IECEx
DEK 16.0063
• 990 SmartRadar FlexLine without Integrated (HART)
SmartView
Ex d IIB T6 Ga/Gb or Ex d [ia Ga] IIB T6 Ga/Gb according to IECEx KEM 07.0003X
• SmartConn
Ex e [ia Ga] IIB T6 Gb according to IECEx KEM 07.0031

Part Number: 4417760-D10 Installation Guide 12

990 SmartRadar FlexLine
  FM
• 990 SmartRadar FlexLine with Integrated SmartView Class I, Division 1, Groups C and
D, T4, according to 3030575 including optional Integrated SmartView according to
3030575
• 990 SmartRadar FlexLine without Integrated SmartView Class I, Division 1, Groups C and
D, T6, according to 3030575

 CSA
• 990 SmartRadar FlexLine with Integrated SmartView
Class I, Division 1, Groups C and D, T4, Enclosure 4X, Dual Seal Ex d [ia Ga] IIB T4
IP66 / IP67 Ga/Gb, Dual Seal according to 1921040 including optional Integrated
SmartView according to 1921040
• 990 SmartRadar FlexLine without Integrated SmartView
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

 INMETRO
• 990 SmartRadar FlexLine without SmartConn and with Integrated SmartView
Ex d [ia Ga] IIB T4 Ga/Gb According to TÜV 13.0977 X including optional Integrated
SmartView according to TÜV 13.0977 X
• 990 SmartRadar FlexLine without SmartConn and without Integrated SmartView
Ex d [ia Ga] IIB T6 Ga/Gb According to TÜV 13.0977 X
• 990 SmartRadar FlexLine with SmartConn and with Integrated SmartView
Ex d e [ia Ga] IIB T4 Ga/Gb According to TÜV 13.0977 X including optional Integrated
SmartView according to TÜV 13.0977 X
• 990 SmartRadar FlexLine with SmartConn and without Integrated SmartView
Ex d e [ia Ga] IIB T6 Ga/Gb According to TÜV 13.0977 X

2.10 Compliance to FCC, R&TTE, IC

This device complies with EN 302372 of the R&TTE Directive, Part 15 of the FCC Rules, and
RSS-Gen of IC. The device does not cause harmful interference and accepts any
interference received.

WARNING!
Changes or modifications made to this equipment not approved by Honeywell Enraf invalidate the
R&TTE/ FCC/IC authorization to operate this equipment.

CAUTION!
This equipment has been tested. It complies with a Field disturbance sensor device, pursuant to Part
15 of the FCC Rules and FCC-Gen for IC. 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. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This device generates,
uses and radiates radio frequency energy. If this device is not installed and used in accordance with
the instructions, it can cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation.

Part Number: 4417760-D10 Installation Guide 13

990 SmartRadar FlexLine
 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.

2.10.1 EN 302372-1, ANNEX B

The following installation requirements shall be fulfilled:
1 990 SmartRadar FlexLine instruments are required to be installed at a permanent fixed
position at a closed (not open) metallic tank or reinforced concrete tank, or similar enclosure
structure made of comparable attenuating material.
2 Flanges and attachments of the radar equipment shall provide the necessary microwave
sealing by design.
3 Sight glasses shall be coated with a microwave proof coating when necessary (i.e.
electrically conductive coating).
4 Manholes or connection flanges at the tank shall be closed to ensure a low-level leakage
of the signal into the air outside the tank.
5 Whenever possible, mounting of the radar equipment shall be on top of the tank structure with
the orientation of the antenna to pointing in a downward direction.
6 Installation and maintenance of the radar equipment shall be performed by professionally
trained individuals only.

Part Number: 4417760-D10 Installation Guide 14

990 SmartRadar FlexLine
 3 PRODUCT DESCRIPTION

3.1 System Components

B
C

FIG. 3-1 System components

The device has following system components (see figure above):

Description
A 990 SmartRadar FlexLine with separator coupling to radar antenna
B HART SmartView (optional)
C SmartConn (optional)
D Antenna connection (see antenna installation guide)

Part Number: 4417760-D10 Installation Guide 15

990 SmartRadar FlexLine
 3.2 9 9 0 SmartRadar FlexLine

3.2.1 Function
The 990 SmartRadar FlexLine is the core component. It provides the level measurement,
integrates optional sensor data and communicates via the fieldbus to the host computer
system.

3.2.2 Components

FIG. 3-2 General view and components of the FlexConn box (FCB)

Description (see FIG. 3-2)

A Top cover
B Display cover
C FlexConn box and FlexConn cover flange
D FlexConn cover
E Bolts with reduced shank (turn into thread when closing the cover)
F Cable entry
G Connection terminals with identification labels
H Separator coupling (connection between antenna and 990 SmartRadar
I FlexConn box
J Inner cover (do not open, do not touch)

Part Number: 4417760-D10 Installation Guide 16

990 SmartRadar FlexLine
 3.3 HART SmartView

3.3.1 Function
The HART SmartView display can be part of the device. You can order a stand alone HART
SmartView. In this case it is placed in a larger housing. Refer to the display installation guide.

3.4 SmartConn

3.4.1 Function
SmartConn is an optional Ex-e junction box and is only certified for ATEX and IECEx. It
simplifies the external connection of the device and provides additional cable entries.

3.4.2 Components

E
D

FIG. 3-3 Optional Ex-e junction box components

Description
A Enclosure
B Cover
C Cable entry M20 (4x)(optional = 6x)
D Connection to FlexConn box
E Terminals for intrinsic safe and non-intrinsic safe connections

Part Number: 4417760-D10 Installation Guide 17

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 3.5 Configurations
The device has several possible configurations. They can differ in:
 Measurement accuracy
 Allowed process temperature ranges
 Chemical compatibility
 Allowed tank pressure
 Weights and Measurements (W&M) approval
 Explosion safety approvals
 Optional features like HART SmartView (Display) and SmartConn (junction box)
 Allowed process temperature (Gas temperature)

Part Number: 4417760-D10 Installation Guide 18

990 SmartRadar FlexLine
 4 INSTALLATION

4.1 Safety

4.1.1 General

WARNING!
Make sure all 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.

CAUTION!
Do not make any additional holes in the housing. Do not incorporate rotating machines or other
devices, which create turbulence inside the FlexConn box.

WARNING!
Always clean the FlexConn box flange, when you open or before you close the housing.

WARNING!
Make sure that no explosive gas mixtures build up in the working area.

4.1.2 Hazardous Zone

WARNING!
POTENTIAL ELECTROSTATIC CHARGING HAZARD

• Avoid generation of static electricity.

• In case a OneWireless 990 SmartRadar FlexLine is installed, do NOT wipe the surface of the
antenna with dry cloth, and do NOT clean its surface with a solvent.

If electrostatically charged, discharge of the antenna surface to a person or a tool could ignite a
surrounding hazardous atmosphere.

4.2 Receipt
 Open the box
 Make sure the following items are in the box:
• The device
• The communication antenna (OneWireless option only)
• Safety instruction
• Declaration of conformity
• Installation guide
• Relevant certificates
• Safety manual when ordered with SIL option
• Control drawing booklet (FM, CSA)
• Check list assembled device
 Inspect the package upon arrival. Make sure the items are not damaged. Contact your
local representative or Honeywell Enraf in the event of damage.

Part Number: 4417760-D10 Installation Guide 19

990 SmartRadar FlexLine
 NOTE:
Do not throw away the packaging. The packaging is necessary for further transport on site. The
packaging is necessary if the device is returned for service or warranty.

4.3 Storage

4.3.1 Storage of Uninstalled Devices

Keep the device in its original packing during storage. Keep the device indoors during
storage.
Ambient conditions
Temperature -50 to +85 °C (-58 to +185 °F)
(when installed with HART SmartView: -30 to +85 °C) (-22 to +185 °F)
Humidity 10 to 90%

4.3.2 Storage of Installed Devices

If you do not use an installed device for a longer period, we recommend not to disconnect the
mains connection line. If this is not possible, put some moisture-absorbing material (e.g. silica
gel) into the electronic compartment.

4.4 Before Installation

Make sure following conditions are met:
 The antenna- and tank separator are already installed on the tank (see 990 SmartRadar
FlexLine Antennas installation guide).
 The top cover of the device can open without obstruction. For required distances for
installation, see FIG. 4-1.

FIG. 4-1 Distances to installed device (see table below)

Part Number: 4417760-D10 Installation Guide 20

990 SmartRadar FlexLine
 mm inches
A 550 21.7
B 260 10.2
C 430 16.9
D 300 11.8

Device weight = 16.3 kg (36 lbs)

4.5 Installation Overview

Installation of the 990 SmartRadar FlexLine requires the following steps:
1 Mechanical installation of the device on the tank separator.
2 Preparations for connection
3 Installing the compound glands and conduits
4 Electrical connection
5 Finishing installation
These steps are further explained in the following sections.

4.6 Mechanical Installation

4.6.1 Connect 990 SmartRadar FlexLine to Tank Separator

FIG. 4-2 Separator coupling (A) and tank separator (C)

 Place device separator coupling (A) on tank separator (C).

Make sure the pin of the separator coupling fits into the corresponding opening of the tank
separator.
 Turn ring (B) clockwise to fasten the device. Fasten ring hand tight.

Part Number: 4417760-D10 Installation Guide 21

990 SmartRadar FlexLine
 4.6.2 Mount Communication Antenna (OneWireless option only)

In case of a OneWireless 990 SmartRadar FlexLine (option), a communication antenna and a

lightning arrester (option) are delivered according to the customer’s order.

 In case a 990 SmartRadar FlexLine device is ordered with the lightning arrester, first
install the Lightning arrester on top of the antenna feedthrough, and then mount the
communication antenna by screwing it clockwise upon the lightning arrester (see picture
below).

communication antenna

lightning arrester 1

NOTE:
The lightning arrester protects the inside electronics from lightning damage. Although it will protect
against multiple discharges, it can be replaced as a preventive maintenance action. Preventive
maintenance interval depends on location, position of the equipment, grounding, and other protection
measures installed. Lightening arresters are recommended only for regions which are lightening
prone.

Part Number: 4417760-D10 Installation Guide 22

990 SmartRadar FlexLine
 

 In case a 990 SmartRadar FlexLine device is ordered without the lightning arrester, mount
the communication antenna by screwing it clockwise upon the antenna feedthrough (see
picture below)

Communication Antenna 2

OR

Part Number: 4417760-D10 Installation Guide 23

990 SmartRadar FlexLine
 4.7 Preparations for Installation with SmartConn

4.7.1 Open Cover of SmartConn

FIG. 4-3 SmartConn box

 Loosen the 4 bolts (A) of the cover. Use an Allen key (4 mm)
 Remove cover

Part Number: 4417760-D10 Installation Guide 24

990 SmartRadar FlexLine
 4.8 Preparations for Installation without SmartConn

4.8.1 Remove Top Cover

FIG. 4-4 Removing the top cover

 Open display cover (A)

 Move up top cover (B) at the front
 Remove top cover

Part Number: 4417760-D10 Installation Guide 25

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 4.8.2 Open the Cover

FIG. 4-5 Opening the cover of the device

 Loosen the 16 bolts of the cover. Use an Allen key (8 mm).

CAUTION!
Make sure the 4 bolts (A) at the side of the hinge are entirely screwed into the cover and do not
protrude beyond the flange of the cover. Otherwise the flange of the housing can be damaged when
closing the cover, and this will invalidate the Ex certificate!

 Open cover

4.9 Installing the Cable Glands and Stopping Plugs with SmartConn

CAUTION!
Only use Ex-e or flameproof certified materials of an IP 66/67 value.

CAUTION!
Improper installation of cable glands or stopping plugs will invalidate the Ex approval of the 990
SmartRadar FlexLine.

Part Number: 4417760-D10 Installation Guide 26

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 4.9.1 Cable Glands
 Use increased safe (Ex-e) M20 cable glands with an IP 66/67 value.
See the type plate on the device.

NOTE:
Install the cable glands according to the instructions provided by the manufacturer.

4.9.2 Unused Cable Inlets

 Seal unused cable inlets with approved M20 threaded stopping plugs.

4.10 Installing the Compound Glands, Conduits, and Stopping Plugs without SmartConn
Depending on local regulations, this device can be cabled by using compound glands, direct entry, or
conduits.

CAUTION!
Only use Ex-d certified materials of an IP 66/67 value.

CAUTION!
Improper installation of cable glands, conduits, or stopping plugs will invalidate the Ex approval of the
990 SmartRadar FlexLine.

NOTE:
Only for use in ATEX and IEC Ex approved installations.

4.10.1 Compound Glands

 Use ¾” explosion proof (Ex-d) compound glands with an IP 66/67 value.

NOTE:
Install the compound glands according to the instructions provided by the manufacturer.

4.10.2 Conduits
 Use explosion proof (Ex-d) conduits with an IP 66/67 value. See the type plate on the
device.

WARNING!
If the 990 SmartRadar FlexLine is installed in a hazardous area:
• Metal conduits must be used, size 3/4”.
• Stopper boxes must be installed within 45 cm (18”) of the device to seal the cabling in the conduit.

Part Number: 4417760-D10 Installation Guide 27

990 SmartRadar FlexLine
 NOTE:
Install the conduits according to the instructions provided by the manufacturer.

4.10.3 Unused Cable Inlets

 Seal unused cable inlets with approved 3/4” threaded stopping plugs.

4.11 Electrical Connection

WARNING!
Any externally connected devices connected to mains power shall have reinforced or double
isolation.

CAUTION!
Cables must always comply with the defined cable specifications.

CAUTION!
• Minimum incoming wire cross section should be at least 0.2 mm2 and may consist of a single-,
fine- or multi- wire. With the use of wire with a cross section between ≥0.2 mm2 and <0.5 mm2,
the maximum current I [A] should be reduced to a maximum of I = 0.55 A.
• With a minimum wire cross section of ≥0.5 mm2 the maximum current I should not be higher
than 3 A and may consist of a single-, fine- or multi-wire.

NOTE:
The field cabling entering the SmartConn box must be as short as possible.

4.11.1 Grounding
The 990 SmartRadar FlexLine housing must be properly grounded to the ground reference
(generally the tank), according to local regulations. This is a safety grounding requirement.

WARNING!
When measuring the ground resistance, use a suitable instrument that is approved for use in
hazardous areas.

WARNING!
Safety depends on proper grounding. Check the resistance of the ground connection directly after
installation. The measured ground resistance must be below the maximum prescribed by local and/or
national grounding requirements.

4.11.2 Introduction

WARNING!
The intrinsically safe options have been certified for use in hazardous areas. Make sure that the
certificate of approval is available on site and act in accordance with the instructions as given in the
certificate.

Part Number: 4417760-D10 Installation Guide 28

990 SmartRadar FlexLine
 WARNING!
Intrinsically safe wiring must be separated from all other wiring. The cable lay-out must be in
accordance with local and/or national regulations.

NOTE:
Connect the armouring of the cable externally in the cable gland at both ends of the cable.

4.11.2.1 Location
The terminal compartment is located at the rear, inside of the device (see FIG. 4-7). If
there is a SmartConn present, you use the terminals of the SmartConn (see FIG. 4-6).
These terminals are numbered identical to the terminal compartment in the device.

4.11.2.2 Connections
The intrinsically safe cabling must enter at the gland (C) only. This entry is marked "Ex-i".
See FIG. 4-6. Blue marked cables are recommended for the intrinsically safe options.

FIG. 4-6 Ex-i entry with SmartConn

Description
A Blue terminals, for intrinsically safe connections
B Grey terminals, for non-intrinsically safe connections
C Glands for intrinsically safe cabling only

NOTE:
The SmartConn box is also available with 6 cable entries.

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 4.11.2.3 Terminals

FIG. 4-7 Terminal layout without SmartConn

The terminal compartment is divided into two zones:

 Blue terminals (A), for intrinsically safe connections, such as HART, VITO and HART
SmartView.
 Grey terminals (B), for non-intrinsically safe connections.

The indices of the terminals are variable. For each option there are indices on the
terminal row. They are specified in a label attached in front of the terminal row, as is
schematically indicated in figure 4.8.
The terminals for the power supply are standard.

Part Number: 4417760-D10 Installation Guide 30

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 FIG. 4-8 Terminal labelling

4.11.2.4 General Procedure

 Connect the wiring to the terminals with the numbers as shown in the tables in the
following sections.

4.11.3 Non-intrinsically Safe Connections

The non-intrinsically safe connections are connected to the grey wiring terminal.
If local and or national regulations allow, the power supply, Enraf fieldbus, and hardware
relay outputs may be combined into one, unshielded, cable.
A separate cable may also be used for each.

4.11.3.1 Power Supply

 Connect the power supply to either:
• DC: 24 - 65 Volt
• AC: 65 - 240 Volt

NOTE:
The DC polarity is not critical.

NOTE:
Install an explosion proof mains switch or circuit breaker in the mains cable to the 990 SmartRadar
FlexLine preferably nearby the device.

Part Number: 4417760-D10 Installation Guide 31

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 Cable specifications
Type Suitable for the 990 SmartRadar FlexLine power rating, and approved for
use in hazardous areas

Label Parameters
00. Vin-a/L 24-65 Vdc -15/+10%
01. Vin-b/N 65-240 Vac -15/+10%
50/60 Hz ± 10%
Automatic selection

4.11.3.2 Enraf Fieldbus (BiPhase Mark)

Cable specifications
Type Twisted pair; Rmax = 200 Ohm /line, Cmax = 1 μF
Maximum length 10 km

Label Parameters
06. or 54 TL1 1200/2400/4800 bps
07. or 55 TL2 Selection by software

4.11.3.2.1 Topology
A maximum of 10 devices can be connected to the Enraf field bus line.

4.11.3.3 Emerson TRL/2 Field Bus (CAN-TRL2)

Cable specifications
Type 18 AWG (minimum) with shielded twisted pair, with max 8 multi Gauge
connections
Maximum length 4 km

Label Parameters
06. or 54. TL1 4800 bps
07. or 55. TL2

Part Number: 4417760-D10 Installation Guide 32

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 4.11.3.4 Host Communication EIA 485

Cable specifications
Type Twisted pair, shielded
Maximum length 1200 meter

NOTE:
If necessary the ‘common’ of the EIA 485 may be connected to the ground GND_ISO.

Label Parameters
11. or 89. 485A 1k2/2k4/4k8/9k6/19k2/38k4 bps
12. or 90. 485B Selection by software
13. or 91. GND_ISO

4.11.3.4.1 Topology

Up to 31 gauges can be connected to one EIA 485 Host communication. The gauges are
connected in parallel, as described in figure 4.9.

EIA 485 Field bus

13. GND_ISO 13. GND_ISO 13. GND_ISO

12. 485B 12. 485B 12. 485B
11. 485A 11. 485A 11. 485A

FIG. 4-9 EIA 485 topology

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 4.11.3.5 Host Communication EIA 232

Cable specifications
Type Shielded
Maximum length 15 meter

Label Parameters
08. or 86. 232RX 38k4/19k2/9k6/4k8/2k4/1k2 bps
09. or 87. 232TX Selection by software
10. or 88. GND_ISO

4.11.3.5.1 Topology

EIA 232 Host communication is for point-to-point communication. One gauge can be
connected per host.

EIA 232 Field Bus

10. GND_ISO
08. 232RX
09. 232TX

FIG. 4-10 EIA 232 topology

4.11.3.6 Hardware Relay Outputs (FII-DO or FII-ALM)

The hardware relay outputs can be used as an alarm signal or to operate a remote device.
The signals corresponding with the terminal labels are programmed during commissioning.

Cable specifications
Type Approved for use in hazardous areas and suitable for the specified power
rating.

Part Number: 4417760-D10 Installation Guide 34

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 4.11.3.6.1 FII-DO

Label Parameters
14. or 78. Ry1_a Vmax = 125 Vac, Imax = 0.5 A via double isolated transformer
15. or 79. Ry1_b Vmax = 110 Vdc, Imax = 0.3 A
Pmax = 30 W
NO/NC by factory jumper (default =NO)
16. or 80. Ry2_a Vmax = 125 Vac, Imax = 0.5 A, via double isolated transformer
17. or 81. Ry2_b Vmax = 110 Vdc, Imax = 0.3 A
Pmax = 30 W
NO/NC by factory jumper (default = NO)

4.11.3.6.2 FII-ALM

Label Parameters
18. or 82. Ry3_a Vmax = 250 Vac, Imax = 2 A
19. or 83. Ry3_b Vmax = 40 Vdc, Imax = 2 A
Pmax = 500 W
NO (normally open)
20. or 84. Ry4_a Vmax = 250 Vac, Imax = 2 A
21. or 85. Ry4_b Vmax = 40 Vdc, Imax = 2 A
Pmax = 500 W
NO (normally open)

4.11.3.7 HCI-HAO

Cable specifications
Type Shielded twisted pair
Maximum length 1200 meter

Label Parameters
46. or 58. 4-20 mA +
47. or 59. 4-20 mA -

Part Number: 4417760-D10 Installation Guide 35

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 4.11.3.8 SIL Overfill and Underfill Protection (CAN-SIL)

Label Parameters
60. AO-PAS + Iin / Iout = 1 ….24 mA
61. AO-COM Vin / Vout = 10…24.5 V
62. AO-ACT -

If the sensor powers the loop connect sensor between terminals 60 AO-Pas + and 61 AO-ACT –

If the 990 SmartRadar FlexLine powers the loop connect sensor between terminals 61 AO-COM
+ and 62 AO-ACT –

Label Parameters
64. DO1_a Vmax = 250 Vac, Imax = 2 A
65. DO1_b Vmax = 40 Vdc, Imax = 2 A
Pmax = 500 W
66. DO2_a Vmax = 250 Vac, Imax = 2 A
Vmax = 40 Vdc, Imax = 2 A
67. DO2_b
Pmax = 500 W

4.11.4 Intrinsically Safe Connections

The intrinsically safe connections are connected to the blue wiring terminal. When the
electrical parameters of the cable are unknown, the following values may be used in the
calculations:
Capacitance: 197pF/m (60 pF/ft)
Inductance: 0.66μH/m (0.020μH/ft).

4.11.4.1 VITO
For temperature and water bottom measurement.

Cable specifications
Type Twisted pair, shielded. Rmax = 25 Ω / line
Maximum length 1000 meter

Label Parameters
24. or 22. or 56. V_Loop [Ex ia] IIB
25. or 23. or 57. GND_Loop Uo = 23.1 V
Io = 124 mA
Po = 0.6 W
Co = 1.0 μF
Lo = 9 mH

Part Number: 4417760-D10 Installation Guide 36

990 SmartRadar FlexLine
 NOTE:
If existing installations have terminals 22 (V_Loop) and 23 (GND_Loop), VITO must be
connected between them.

4.11.4.1.1 Topology

Terminals for HART and VITO are combined. You can connect a maximum of 5 HART devices
or a combination of 1 VITO sensor and 3 HART devices.

NOTE:
Each set of HART terminals, 22-23, 24-25 or 56-57 is connected to 1 internal HART board.
Each Hart board can supply its connected HART loop with a current of maximum 24 mA
Additionally, all boards have the same set of Ex-i parameters.

4.11.4.2 HART

Cable specifications
Type Twisted pair, shielded. R max = 25 Ω / line
Maximum length 1000 meter

Label Parameters
24. or 22. or 56. V_Loop [Ex ia] IIB
25. or 23. or 57. GND_Loop Uo = 23.1 V
Io = 124 mA
Po = 0.6 W
Co = 1.0 μF
Lo = 9 mH

4.11.4.2.1 Topology

A maximum of 5 HART devices, or 3 HART devices if VITO is present, can be connected to

each HART connection.

CAUTION!
When an integrated HART SmartView is installed or the connector is present for portable HART
SmartView Connectivity this counts as 1 HART device on terminals 24 and 25.

CAUTION!
Before connecting the HART devices:
Make sure the sum of the start-up currents not to exceed the parameters.

Part Number: 4417760-D10 Installation Guide 37

990 SmartRadar FlexLine
 FIG. 4-11 HART Topology

4.11.4.3 FII-RTD

Cable specifications
Type Shielded. Rmax = 100 Ω / line
Maximum length 150 meter

4.11.4.3.1 RTD, 4-Wire Connection (Board ID = 2)

Label Connections diagram Parameters

30. RTD1_S- R c1 [Ex ia] IIB/IIC
31. RTD1_com Uo = 8.61 V
Io = 58 mA
32. RTD1_pos RTD1
Po = 0.13 W
33. RTD1_S+
Co = 1.0 μF
34. RTD2_S-
Lo = 10.5 mH
35. RTD2_com
R c2
36. RTD2_pos
37. RTD2_S+
RTD2

Part Number: 4417760-D10 Installation Guide 38

990 SmartRadar FlexLine
 4.11.4.3.2 RTD, 3-Wire Connection (Board ID = 3)

Label Connections diagram Parameters

30. RTD1_S- R c1 [Ex ia] IIB/IIC
31. RTD1_com Uo = 8.61 V
Io = 58 mA
32. RTD1_pos RTD1
Po = 0.13 W
Co = 1.0 μF
34. RTD2_S- Lo = 10.5 mH
35. RTD2_com R c2
36. RTD2_pos
RTD2

4.11.4.3.3 MPT - MRT (Board ID = 4)

Label Connections diagram Parameters

38. S- Rc [Ex ia] IIB/IIC
39. com Uo = 8.61 V
Io = 58 mA
40. R1
Po = 0.13 W
41. R2
R1 Co = 1.0 μF
42. R3 Lo = 10.5 mH
R2
43. R4
44. R5 R3
45. R6
R4
R5
R6

4.11.4.4 Stand-alone SmartView Display

The labelling on the wiring terminal in the SmartView is identical to the labelling in the 990
SmartRadar FlexLine.

Cable specifications
Type 4-wire, shielded
Maximum length 50 meter

Part Number: 4417760-D10 Installation Guide 39

990 SmartRadar FlexLine
 Label Parameters
26. SGND [Ex ia] IIB
27. Vsafe_+ Uo = 14.2 V
Io = 522 mA
28. Safe_A
Po = 1.7W
29. Safe_B
Co = 2.18 μF
Lo = 0.25 mH

4.11.4.5 Stand-alone HART SmartView Display

Cable specifications
Type 2-wire, shielded
Maximum length 1000 meter
Refer to HART Communication Foundation document number HCF_SPEC-
54 (FSK Physical Layer Specification) for detailed length calculations.

Connection table

Label 990 SmartRadar 990 SmartRadar Label HART HART SmartView

FlexLine FlexLine SmartView parameters
Parameters

24. or 22. or 56. V_loop [Ex ia] IIB 2. Loop + Ex ia IIB T4 Gb

25. or 23. or 57. GND_Loop Uo = 23.1 V 1. Loop - Ui = 30 V
Io = 124 mA Ii = 200 mA
Po = 0.6 W Pi = 0.7 W
Co = 1.0 μF Ci = 10 nF
Lo = 9 mH Li = 16 μH

4.11.4.5.1 Topology

A maximum of 5 HART devices, or 3 HART devices if VITO is present, can be connected to

each HART connection.

CAUTION!
When an integrated HART SmartView is installed or the connector is present for portable HART
SmartView Connectivity this counts as 1 HART device on terminals 24 and 25.

Part Number: 4417760-D10 Installation Guide 40

990 SmartRadar FlexLine
 4.11.4.6 RMA805 Enraf FlexLine Remote Indicator

Cable specifications
Type 2-wire, shielded
Maximum length 1000 meter
Refer to HART Communication Foundation document number HCF_SPEC-
54 (FSK Physical Layer Specification) for detailed length calculations.

Connection table

Label 990 SmartRadar 990 Label RMA805 RMA805 Enraf

FlexLine SmartRadar Enraf FlexLine FlexLine Remote
FlexLine Remote indicator
Parameters indicator parameters

24. or 22. or 56. V_loop [Ex ia] IIB Loop + Ex ia IIC T4 Ga

25. or 23. or 57. GND_Loop Uo = 23.1 V Loop - Ui ≤ 30 V
Io = 124 mA Ii ≤ 225 mA
Po = 0.6 W Pi = 0.9 W
Co = 1.0 μF Ci = 3.9 nF
Lo = 9 mH Li = 0 μH

4.11.4.6.1 Topology

A maximum of 5 HART devices, or 3 HART devices if VITO is present, can be connected to

each HART connection.

CAUTION!
When an integrated HART SmartView is installed or the connector is present for portable HART
SmartView Connectivity this counts as 1 HART device on terminals 24 and 25.

4.12 Finishing Installation with SmartConn

CAUTION!
Make sure the separation between intrinsic and non intrinsic cabling is sufficient and complies with
any local and/or national regulations.

 Replace the cover on the SmartConn.

 Tighten the 4 bolts of the cover. Tighten the bolts crosswise and gradually (tighten one
bolt to a small degree and move to the next one until all bolts are fully tightened). Use an
Allen key (4 mm). The installation is now completed.

Part Number: 4417760-D10 Installation Guide 41

990 SmartRadar FlexLine
 4.13 Finishing Installation without SmartConn

WARNING!
Tighten all bolts with a torque of 30 Nm (22 ft·lb) to prevent danger of explosion!

CAUTION!
Always clean the flange of the housing and the cover, before you close the cover.

4.13.1 Close the Cover of the Device

WARNING!
Make sure the flange of the housing is clean and the O- ring is not damaged before closing the cover.

 Close the cover. Make sure that the cover does not squeeze any cables inside the
housing.
 Tighten the 16 bolts of the cover. Tighten the bolts crosswise. Use an Allen key (8mm).

4.13.2 Replace the Top Cover

 Open the display cover.

 Place the 2 hooks at the rear of the top cover behind the axis of the cover.
 Push down the top cover carefully. The installation is now completed.

4.14 TRL/2
The 990 SmartRadar FlexLine gauges act as Rex gauges with the help of CAN-TRL/2 card.
The CAN-TRL/2 communication card for 990 SmartRadar FlexLine gauge is added to
integrate to the Emerson system. The Rex Gauge and Tank master (Emerson tank software)
communicates over TRL/2 network and uses Modbus protocol. When Rex Gauge is
replaced in field with 990 SmartRadar FlexLine gauge, the tank master gets the data (for
example: product level, temperature) from 990 SmartRadar FlexLine gauge same as Rex
Gauge.
The 990 SmartRadar FlexLine gauge has the capability to connect directly to Emerson TRL/2
field bus. The Rex or TRL/2 RTG gauges can be replaced with 990 SmartRadar FlexLine
gauge with great ease, minimum modifications, and quick turnaround time. The 990
SmartRadar FlexLine gauge communicates with TRL/2 FSK protocol over Modbus RTU and
can interface with FCU 2160/65/75 or tank hub 2410 or FBM 2180.
The system integrates with TankMaster Win OPI and provides level, temperature, and other
inputs to the system. Replace the Rex gauge (with or without DAU) with 990 SmartRadar
FlexLine gauge and RDU with SmartView display.

Part Number: 4417760-D10 Installation Guide 42

990 SmartRadar FlexLine
 The figure 4-12 shows the Emerson system with Rex gauges, and one of its gauge is
replaced by 990 SmartRadar FlexLine gauge.

FIG. 4-12 System Architecture - Rex Replaced with 990 SmartRadar FlexLine

Part Number: 4417760-D10 Installation Guide 43

990 SmartRadar FlexLine
 4.14.1 Specification TRL/2 990 SmartRadar FlexLine Gauge

Detailed Specification 990 SmartRadar FlexLine in Emerson TRL/2 Field Bus

Protocol Modbus RTU
Communication TRL/2 100/90 KHz FSK
Cable 18 AWG (minimum) with shielded twisted pair, max 4 kms with max
8 multi drop Gauge connections
Data Rate 4800 Baud
Readout System TankMaster Win OPI Win Setup
Configuration Enraf Engauge tool
Configuration Modem SmartLink TRL/2 Master, can be used in control room or on table
configuration
Power Supply 100-240 VAC
Gauge Compatibility 5900, 5400, 5300, TRL/2 RTG (old gauges)
Temperature input Compatible to both With DAU (14) and Without DAU (6). With DAU
is replaced with VITO and HRT Without DAU is replaced with RTD
MPT/MRT.
Analog I/O HART & Option AI HART AO Relay
Relay combination 1 2 0 0 2
2 1 1 (3 Slaves) 1 1
Remote Display SmartView Display
Water Level Sensor With VITO Water and temperature combination probe

4.14.2 Electrical Specifications - CAN TRL/2 PWA

Overview of electrical specifications:

In the physical layer, Logic 1 is represented by 100kHz and Logic 0 by 90khz:(+/-3%).
The baud rate is 4800(+/-3%), 8 bits and 1 stop bit. Voltage levels: 3.6V +/- 10%.

Power rating:
At 12V Nominal current drawn by TRL/2 module alone is 40mA(+/- 10%), it means the power
consumption is 480mW(+/-10%).
The worst case current/power drawn with below mentioned conditions is

 All LED's ON.

 Loaded with load equivalent to maximum 8 gauges connected together at TRL/2 field port.
 The current noted is 60mA, it means the total power consumption is 720mW.

Part Number: 4417760-D10 Installation Guide 44

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 4.14.3 Troubleshooting

4.14.3.1 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 FlexConn and GPU address provided in FCM-TRL/2 card
(Re-check gauge and GPU of gauge is same as entered in the FCM-TRL/2 card before
scanning the gauge).

4.14.3.2 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 FlexConn 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 FlexConn board for which level parameter is linked and is not healthy then switch
off the gauge and remove the unhealthy FlexConn 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 FlexConn 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:
 Reset the gauge and repeat all the steps from step 1.

4.14.3.3 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 NOVRAM
of HCI-TRL/2 gauge then provide all gauge addresses and rescan the gauge.
3. If gauge scan Time out error appears then restart SmartLink and try to scan again (check gauge
address mentioned in FCM-TRL/2).

4.14.3.4 SmartLink Scan Issue

1. Scan SmartLink 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 SmartLink from Engauge Tool.

Part Number: 4417760-D10 Installation Guide 45

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 4.14.3.5 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”.
4. Scan the gauge again.

Part Number: 4417760-D10 Installation Guide 46

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 5 TECHNICAL DATA

5.1 Weight and Dimensions

FIG. 5-1 990 SmartRadar FlexLine and SmartConn dimensions

mm inches
A 300 11.82
B 330 12.99
C 90 3.54
D 220 8.66
E 70 2.76
F 260 10.24

Weight = 13.6 kg (36 lbs).

Observe the environmental conditions for safe use:


 The device is suitable for indoor and outdoor use
 Ambient Operating Temperature Range from -40°C (-40°F) up to +65°C (149°F).
 Maximum elevation 2000 meter.
 Relative humidity (non condensing) 10 - 95%
 IP rating (according to IEC 60529) 66/67
 Pollution degree 2 when the main cover is opened during installation and service. This can
be achieved in a controlled environment with suitably reduced condensation or airborne
pollution. (according to IEC 60079-7)

Part Number: 4417760-D10 Installation Guide 47

990 SmartRadar FlexLine
Part Number: 4417760-D10 Installation Guide 48
990 SmartRadar FlexLine
Part Number: 4417760-D10 Installation Guide 49
990 SmartRadar FlexLine
Part Number: 4417760-D10 Installation Guide 50
990 SmartRadar FlexLine
 For service-related questions, contact:

Technical Assistance Centre

Phone:
+1 800 423 9883 or +1 215 641 3610
E-mail:
HFS-TAC-SUPPORT@honeywell.com

Copyright © 2020 - 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.
For More Information
To learn more about Honeywell Enraf’s
solutions, contact your Honeywell Enraf
account manager or visit
www.honeywellenraf.com.

Americas Asia Pacific

Honeywell Enraf Americas, Inc. Honeywell Pte Ltd.
1250 West Sam Houston Pkwy S. 17 Changi Business Park Central 1
Houston, TX 77042 Singapore 486073
Phone: +65 6355 2828
USA
Email: enraf-sg@honeywell.com
Phone: +1 (480) 293-2042
Email: enraf-us@honeywell.com

Europe, Middle East and Africa

Honeywell Enraf
Delftechpark 39
2628 XJ Delft
The Netherlands
Phone: +31 (0)15 2701 100 4417760 Rev. D10
Email: enraf-nl@honeywell.com © June 2020