Manual 854 XTG

Installation guide
854 XTG
Level Gauge
June 2010
Part no. 4416.276
Revision 6
Enraf B.V.
P.O. Box 812
2600 AV Delft
Netherlands
Tel. : +31 15 2701 100

Fax : +31 15 2701 111
E-mail : [email protected]
Website : http://www.honeywellenraf.com
Installation guide 854 XTG Page 1

Preface
Preface
The Honeywell Enraf 854 XTG is a servo gauge which measures the liquid level and can also be
programmed to measure two additional interface levels.
This installation guide is intended for technicians involved with the mechanical and electrical
installation of the Honeywell Enraf 854 XTG Servo Gauge.
EC declaration of conformity
Refer to the EC declaration of conformity, shipped with the instrument.
Note:
All connections to the instrument must be made with shielded cables with exception of the
mains, alarm outputs and Honeywell Enraf field bus cable. The shielding must be grounded in
the cable gland on both ends of the cable.
Legal aspects
The mechanical and electrical installation shall only be carried out by trained personnel with
knowledge of the requirements for installation of explosion-proof equipment in hazardous areas.
The information in this installation guide is the copyright property of Enraf B.V., Netherlands.
Enraf B.V. disclaims any responsibility for personal injury or damage to the equipment caused by:
• Deviation from any of the prescribed procedures;

• Execution of activities that are not prescribed;
• Neglect of the general safety precautions for handling tools, use of electricity and
microwave radiation.
The contents, descriptions and specifications in this installation guide are subject to change
without notice. Enraf B.V. accepts no responsibility for any errors that may appear in this manual.
Additional information
Please do not hesitate to contact Honeywell Enraf or its representative if you require additional
information.
Page 2 Installation guide 854 XTG

Safety
Safety
Safety aspects of 854 XTG
Warning
Do not use the instrument for anything else than its intended purpose.
The housing of the 854 XTG is explosion-proof:
• II 1/2 G Ex d IIB T6 Ga/Gb; II 1/2 G Ex d [ia Ga] IIB T6 Ga/Gb acc. to KEMA 02ATEX2193 X,
certified by KEMA, Netherlands
• Ex d IIB T6 Ga/Gb; Ex d [ia Ga] IIB T6 Ga/Gb; acc. to IECEx KEM 10.0007X,
certified by KEMA, Netherlands
• Class I, Division 1, Groups B, C & D, in acc. to ANSI/NFPA No. 70,
certified by Factory Mutual Research USA (FM no.: 5Y2A9.AX).
Environmental conditions for the 854 XTG are:
ambient temperature : -40 to + 65 °C (-40 to +149 °F)

operating pressure : max. 6 bar
relative humidity : 0 - 100 %
ingress protection : IP65 (NEMA 4), suitable for outdoor installation
The drum compartment, which is in contact with the tank atmosphere, is separated from electronic
compartment. A magnetic coupling transfers the drum movement (hence, displacer movement) to
electronic compartment.
Wiring for intrinsically safe options, such as temperature or pressure measurement, is fed via two
separate cable entries.
The covers of electronic and terminal compartment are locked by means of a setscrew, which
prevents accidental opening.
Warning
Improper installation of cable glands, conduits or stopping plugs will
invalidate the Ex approval of the 854 XTG.

Safety
Personal safety
The technician must have basic technical skills to be able to safely install the equipment.
When the 854 XTG is installed in a hazardous area, the technician must work in accordance with
the (local) requirements for electrical equipment in hazardous areas.
Warning
In hazardous areas it is compulsory to use personal protection and safety gear such as:
hard hat, fire-resistive overall, safety shoes, safety glasses and working gloves.
Avoid possible generation of static electricity.

Use non-sparking tools and explosion-proof testers.
Make sure no dangerous quantities of combustible gas mixtures

are present in the working area.
Never start working before the work permit has been signed by all parties.
Pay attention to the kind of product in the tank. If any danger for health,
wear a gas mask and take all necessary precautions.
Safety conventions
“Warnings”, “Cautions” and “Notes” are used throughout this installation guide to bring special
matters to the immediate attention of the reader.
• A Warning concerns danger to the safety of the technician or user;

• A Caution draws the attention to an action which may damage the equipment;
• A Note points out a statement deserving more emphasis than the general text, but not
requiring a “Warning” or a “Caution”.

General precautions
General precautions
Caution
During transport of the gauge the motor lock block should be locked.
This is for protection of the weighing system.
Figure 1 Motor (un)locking
Tools required:
Hex Allen-key for screw M4 (length minimal 22 mm) part No.: 6121.030
Tommy bar part No.: 2998.024
Caution
The box in which the 854 arrives also contains the measuring drum. This is a precision
measuring device and shall only be installed by a qualified commissioning engineer.
Accurate measurement requires an undamaged and clean drum.
Treat this drum with care !

Mechanical installation
Note:
The entire installation procedure shall be in accordance with national, local and company
regulations.
Preparation for transportation of the gauge
Caution
Do not transport the instrument with the motor unlocked. Refer to figure 1 for motor locking.
Drum should be transported in original protective box. Drum and displacer shall only be installed
by a qualified commissioning engineer.
Process connection
The flange of the 854 XTG is standard 2" 150 lbs, ff, acc. to ANSI B16.5. Select gasket that is
suitable for flange type, maximum pressure and the products to be stored.
Caution
Verify that tank or drum compartment is depressurized before opening
tank or drum compartment cover of 854 XTG.
The 854 XTG can be adapted to various process connection flanges via the adapter/calibration
chamber as specified in Appendix B. Verify that maximum working pressure of adapter/calibration
chamber complies with pressure in your tank.
Note:
When using 854 XTG on pressurized tank, it is recommended to install a suitable valve
between tank and 854 XTG to isolate the instrument from the process when required.
The valve shall have an opening large enough to feed through the displacer.

Orientation of 854 XTG gauge on tank
Mount the gauge in one of the following two ways.
Figure 2 Orientation of the gauge on tank
On a stilling well or guide pole the orientation of the gauge may be chosen freely.
Note:
The weight of the 854 XTG is 16 kg (35 lbs).
Bolts
Secure the gauge adapter by using appropriate (stud) bolts. *)
Flange type Number of (stud) bolts Diameter x minimum

length
2" 150 lbs 4 stud bolts M16 x 80 (5/8" x 3 1/4")
6" 150 lbs 8 bolts M20 x 80 (3/4" x 3 1/4")
6" 150 lbs 8 stud bolts M20 x 110 (3/4" x 4 3/8")
*) ref. to DIN 2527, ANSI B16.5.

Grounding
Warning
For proper grounding of the 854 XTG,
install a copper strip under one of
the flange bolts for each flange.
Place shark rings between flange

and strip (figure 3).
Note:
Also in case of tanks with cathodic
protection, the 854 XTG must be
grounded to the tank.
Cathodic protection can be maintained

by isolating the cabling screen/armouring
or conduit.
Figure 3 Example of flange ground

Electrical installation
The entire electrical installation shall be in accordance with International Standard IEC 79-14 for
electrical equipment to be installed in hazardous areas.
Warning
The instrument may not be opened when an explosive atmosphere may be present.
Failure to do so may cause danger to persons or damage the instrument.
All covers of the 854 XTG must be closed before switching on the power.
Caution
Before opening the electronic and terminal
compartment cover, loosen the setscrews which locks the covers with Allen key 2.5 mm:
Setscrew ‘A’: for electronic compartment cover;

Setscrew ‘B’: for terminal compartment cover.
Figure 4 Setscrews locking the covers
Caution
Do not damage the thread of the covers and instrument and keep the thread free of dirt.
After opening, grease it lightly with anti seize grease.
When closing, never tighten the covers before the threads are properly engaged.
The covers should be turned counter-clockwise until the thread ‘clicks’ in place,
then turn clockwise until the covers are fully closed.
After closing the covers, do not forget to lock it with the setscrew.

Preparing the gauge for electrical installation
Check the mains voltage on the label of 854 XTG. Please contact Honeywell Enraf or its
representative if mains setting does not comply with local mains voltage.
Power rating: 25 VA; frequency: 50 - 60 Hz (∀10%); Imax = 2 A. Allowed supply variations: -20% to
+10%, for 230 Vac only: ±15%. Install an explosion-proof mains switch in the mains supply cable
to each 854 XTG. Specify which switch you need to operate the 854 XTG.
External fusing
The 854 XTG is internally fused on secondary side of transformer (fuses are located on the GPS
board). Therefore, external fuses must be installed in the mains supply cable to each 854 XTG.
Mains voltage Fuse value (in accordance to IEC 127-2-3)

220 Vac or 230 Vac 315 mA slow
110 Vac or 130 Vac 630 mA slow
65 Vac 1 A slow
Cable glands / conduit
Cable glands:
The 854 XTG requires explosion-proof (Ex-d) cable glands.
Note:
Mount the cable glands according to the supplier's instructions.
Conduit:
If the 854 XTG is installed in a hazardous area, threaded rigid metal conduit or threaded steel
intermediate metal conduit shall be used.
Note:
If the 854 XTG is installed in a hazardous area, Ex d certified conduit seals must be applied
directly at the wall of the 854 XTG to seal the cabling in the conduit.
Depending on the wiring configuration, one to four 3/4" NPT threaded cable glands (or rigid
conduits) may be required with the 854 XTG.
Note:
Seal unused cable inlets with an approved 3/4" NPT stopping plug.
Warning
Improper installation of cable glands, conduit or stopping plugs will
invalidate the Ex approval of your 854 XTG.

Grounding
The 854 XTG housing should be properly grounded to the ground reference (generally the tank).
This is a safety grounding requirement. Grounding can be performed by copper strips across the
flanges (refer to section Grounding at mechanical installation), or by a ground wire.
With last mentioned method, use one of the external ground terminals of the 854 XTG.
Note:
Grounding shall be performed in accordance with local regulations.
Caution
Safety depends on proper grounding. Check the resistance of the ground
connection directly after installation. The measured ground resistance shall be
below the maximum prescribed by local grounding requirements.
Warning
When measuring the ground resistance, use a suitable explosion-proof tester.
Lay-out terminal compartment
The terminal compartment of the 854 XTG is

divided in a non-intrinsically safe part and an
intrinsically safe part.
Cable entries are all ¾" NPT.
The non-intrinsically safe cabling may only enter

at the two left hand side cable entries (Figure 5).
Warning
The instrument may not be opened when
an explosive atmosphere may be present
Figure 5 Terminal compartment 854 XTG

Non-intrinsically safe cabling
Mains cabling : Must be suitable for the 854 XTG power rating and, moreover, approved for
the use in hazardous areas.
Honeywell
Enraf field bus : One twisted pair cable is recommended. Rmax = 200 / line; Cmax = 1 µF.
Maximum length: 10 km.
Honeywell Enraf field bus lines may be interchanged. If local regulations allow,
mains and Honeywell Enraf field bus lines may share one cable. Mind the
isolation voltage of the cores in the cable; refer to the International Standard
IEC 61010-1.
Note:
If a quad cable is used and all four cores are twisted together, use two
opposite cores for Honeywell Enraf field bus lines and the two others for
mains.
Relay outputs : Option. The relay output contacts are potential free. Contact rating:
Umax = 50 Vac or 75 Vdc; Imax = 3 A non-inductive. Mind the isolation voltage of
the cores in the cable; refer to the International Standard IEC 61010-1.
Analog output: : Option. Use shielded cable. External supply voltage: 12 to 64 Vdc
Refer to figure 7.
Terminal information:
solid / stranded : 0.5...6 / 1.5...4
flexible / Stranded wire with end : 0.5...4 / 0.5...2.5
Tightening torque range (clamping) : 0.6...0.8 Nm (M 3)
Stripping length / Blade size : 8 / 0.6 x 3.5 mm
Figure 6 Non-intrinsically safe connections

When the voltage exceeds 30 Vdc, an additional

resistor is required.
The permitted operational areas are shown

in figure 7.
Operational area 1 represents the area of operation

without the need for an external
loop resistance.
Operational area 2 shows the area where a

resistance is required.
The power rating of the external resistor depends on

the value of the resistor.
We recommend 1 W / kΩ Figure 7 Selecting the external loop
resistor
Optional RS communication connections
For the cable connections of the mains and alarm contacts, refer to previous section.
Caution
Keep the RS-232C / RS-485 lines as short as possible.
RS-232C : Cable requirements: maximum length 15 metres (50 ft); twisted and shielded.
RS-485 : Cable requirements: maximum length 1200 metres (3900 ft); twisted and shielded.
Figure 8 RS-232C / RS-485 connections

Intrinsically safe options
The cables for the intrinsically safe options shall only be fed through the cable entries at the side of
the intrinsically safe (blue) terminals. Blue marked cables are recommended for the intrinsically
safe options.
Caution
The intrinsically safe options described in this section are explosion-proof certified.
Make sure that the certificate of approval is available on site and act in accordance
with the instructions as given in the approval certificate.
Caution
Intrinsically safe wiring shall be separated from all other wiring.
Cable lay-outs shall be in accordance with local regulations.
Note:
The shield of the intrinsically safe cable shall not be connected inside the 854 XTG housing.
Connect the shield of the cable externally in the cable gland at both ends of the cable.
Device Cable requirements
Spot temperature element : Shielded; Rmax = 12 Ω / line.
Average temp. element : Twisted pair and shielded; Rmax = 25 Ω / line.

(combined water probe) Wiring between the 854 XTG and 762 VITO must be protected with
EMC shielded conduit. Same conditions for connection to 862 MIR.
Pressure transmitters : Twisted pair and shielded; Rmax = 25 Ω / line (only pressure
transmitters with HART protocol).
Pressure transmitter P1 is the bottom transmitter (measures liquid
head) and P3 is the top transmitter (measures vapour pressure).
Note:
If pressure transmitters are connected to HART input 2, it must be verified that the maximum
values for current and power of the HCU option board HART input 2 circuit are not exceeding
the maximum values of the connected pressure transmitters. Refer to Appendix C.
If the values of the HART input 2 circuit are too high, then connect the pressure transmitters to
HART input 1 and the 762 VITO Interface to HART input 2 (only possible when HART input 1
is available!).

Device Cable requirements
977 Tank Side Indicator : Twisted pair and shielded; Rmax = 5 Ω / line; maximum cable length
50 m (160 ft).
Water bottom probe : Twisted pair and shielded; Rmax = 25 Ω / line

(no VITO water sensor) (only with HART protocol).
Note:
If also pressure transmitters are connected, use a junction box for parallel connection of the
pressure transmitters and water bottom probe.
Maximum number of i.s. terminals is 6 (refer to figure 9). Depending on the installed option(s),
some of the i.s. terminals are not present. Valid combinations of i.s. options are:
Sales code
position 4 Optional function(s) Terminals
B Spot temperature Pt100 (+ 977 TSI) 1, 2, 3 (+ 7, 8)
C, W, X 762 VITO Interface (+ 977 TSI) 3, 4 (+ 7, 8)
J 762 VITO Interface + HART device(s) (+ 977 TSI) 3, 4 + 5, 6 (+ 7, 8)
U Spot temperature Pt100 + HART device(s) 1, 2, 3 + 5, 6

Figure 9 Intrinsically safe connections with HCU option board

Appendix
Appendix A Dimensions

Appendix
Appendix B Available adapters

Appendix
Appendix C ATEX approval
The terminal compartment of the 854 XTG level gauge has been ATEX approved as explosion
proof. Hence, explosion-proof Ex d approved glands or conduit are to be used.
Connection requirements of optional boards

The identification label on the 854 XTG indicates whether your instrument is equipped with an
optional board with intrinsically safe measuring circuits.
XPU-2 board (i.s. option), [Ex ia] IIB

Output circuit for 977 TSI:
Max. values : U = 21 V, I = 395 mA, P = 1.41 W
Max. permissible ext. inductance : 0.8 mH
Max. permissible ext. capacitance : 1.27 µF
HCU option board, [Ex ia] IIB

Spot temperature input circuit:
Max. values : U = 23.1 V, I = 221 mA, P = 0.19 W
Max. permissible ext. inductance : 3.5 mH
Max. permissible ext. capacitance : 980 nF
HART input 1 circuit (for 762 VITO Interface):

Max. permissible ext. inductance : 15 mH
HART input 2 circuit (for HART pressure transmitters and/or external water probe):
Max. permissible ext. inductance : 7 mH

Appendix
Appendix D Related documents
Instruction manual 854 XTG level gauge

Instruction manual 854 density option
Instruction manual SPU II hard alarm output contacts
Installation guide 762 VITO Interface & 764, 765 or 766 VITO temperature and/or water sensor
Installation guide 977 Tank Side Indicator
Instruction manual XPU-2 option RS-232C/RS-485

Instruction manual Temperature, Water bottom and Analog output options
Instruction manual HIMS / HTG and vapour pressure (P3) measurement
Instruction manual 847 PET
Installation info 003 “Installation of Pressure Transmitters for HTG and HIMS”

Notes

Notes

Notes

Delftechpark 39
2628 XJ Delft
Tel. :+31 15 2701 100

E-mail : [email protected]
Webiste: http://www.honeywellenraf.com
PO Box 812
2600 AV Delft
The Netherlands
We at Honeywell Enraf are committed to excellence.
Information in this publication is subject to change without notice
Enraf is a registered trade mark. Enraf B.V. Netherlands

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Installation guide

Tel. : +31 15 2701 100

Installation guide 854 XTG Page 1

Refer to the EC declaration of conformity, shipped with the instrument.

• Deviation from any of the prescribed procedures;

Page 2 Installation guide 854 XTG

Safety aspects of 854 XTG

The housing of the 854 XTG is explosion-proof:

Environmental conditions for the 854 XTG are:

ambient temperature : -40 to + 65 °C (-40 to +149 °F)

Installation guide 854 XTG Page 3

Avoid possible generation of static electricity.

Make sure no dangerous quantities of combustible gas mixtures

• A Warning concerns danger to the safety of the technician or user;

Page 4 Installation guide 854 XTG

Figure 1 Motor (un)locking

Treat this drum with care !

Installation guide 854 XTG Page 5

Preparation for transportation of the gauge

Page 6 Installation guide 854 XTG

Orientation of 854 XTG gauge on tank

Mount the gauge in one of the following two ways.

Figure 2 Orientation of the gauge on tank

Flange type Number of (stud) bolts Diameter x minimum

2" 150 lbs 4 stud bolts M16 x 80 (5/8" x 3 1/4")

6" 150 lbs 8 bolts M20 x 80 (3/4" x 3 1/4")

6" 150 lbs 8 stud bolts M20 x 110 (3/4" x 4 3/8")

*) ref. to DIN 2527, ANSI B16.5.

Installation guide 854 XTG Page 7

Place shark rings between flange

Cathodic protection can be maintained

Page 8 Installation guide 854 XTG

Setscrew ‘A’: for electronic compartment cover;

Figure 4 Setscrews locking the covers

Installation guide 854 XTG Page 9

Preparing the gauge for electrical installation

Mains voltage Fuse value (in accordance to IEC 127-2-3)

Cable glands / conduit

Page 10 Installation guide 854 XTG

Lay-out terminal compartment

The terminal compartment of the 854 XTG is

Cable entries are all ¾" NPT.

The non-intrinsically safe cabling may only enter

Figure 5 Terminal compartment 854 XTG

Installation guide 854 XTG Page 11

Non-intrinsically safe cabling

Figure 6 Non-intrinsically safe connections

Page 12 Installation guide 854 XTG

When the voltage exceeds 30 Vdc, an additional

The permitted operational areas are shown

Operational area 1 represents the area of operation

Operational area 2 shows the area where a

The power rating of the external resistor depends on

Optional RS communication connections

Figure 8 RS-232C / RS-485 connections

Installation guide 854 XTG Page 13

Intrinsically safe options

Device Cable requirements

Spot temperature element : Shielded; Rmax = 12 Ω / line.