Hoppe Bordmesstechnik GmbH
Manufacturing instruction
Document No. Designation Revision Issue
Sensor Installation Instructions 1.0 15.07.14
HCG 2011 Sensor
Description-Installation-Instruction
Bild 1
Name: PAR 1/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
Manufacturing instruction
Document No. Designation Revision Issue
Sensor Installation Instructions 1.0 15.07.14
Contents
Contents .........................................................................................................................................2
1 General Information..................................................................................................................3
1.1 Measuring principle..........................................................................................................3
2 Components Of The Sensor System ........................................................................................7
3 Installation ................................................................................................................................9
3.1 Sensor Connection ........................................................................................................11
3.2 KS Sensor Type Installation ...........................................................................................13
3.2.1 Mounting the tank top flange ......................................................................................13
3.2.2 KS Sensor Mounted Via Clamp..................................................................................15
3.2.3 KS-Sensor Mounted Inside Pipe ................................................................................16
3.3 GW Sensor Type Installation..........................................................................................18
3.4 FW Sensor Type Installation ..........................................................................................19
4 Cable guidance ......................................................................................................................20
5 Mounting the HNA connection box .........................................................................................21
6 Insert the cable into the HNA connection box .........................................................................21
7 Check sinter filter....................................................................................................................21
8 Connect sensor cable (Sensor site)........................................................................................22
9 Connect sensor cable (Ship site)............................................................................................23
10 Close the HNA connection box (PICT. 11) .........................................................................24
Sensor typical installation drawing.................................................................................................25
Name: PAR 2/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
Manufacturing instruction
Document No. Designation Revision Issue
Sensor Installation Instructions 1.0 15.07.14
1 General Information
The Hoppe Bordmesstechnik tank level sensors are especially designed and constructed for use
on all kind of ships and offshore plants.
The pressure type sensor is based on a piezoresistive micro chip, which resistance depends on
the applied pressure. The resistance is measured, amplified and converted into an output signal
that is proportional to the fill level of the tank. The HCG 2011 sensor generates a standard signal
4 - 20 mA where 4 mA equals an empty tank.
1.1 Measuring principle
The pressure at the bottom of a filled tank depends only on the densitiy of the fluid, the fill level and
the atmospheric pressure. Based on Pascal’s law you can calculate the pressure p as follows:
p g fluid h p atm
g: standard gravity = 9,81 m/s2 : density of fluid
h: height of fluid in the tank patm: atmosheric pressure (~ 1bar)
Hydrostatic principle
Name: PAR 3/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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If the density of the fluid is known you can determine the fill level by measuring the pressure at the
bottom of the tank:
p p atm
h
g fluid
For that purpose a pressure sensor can be submersed into the liquid or attached to the side of the
tank.
Options for sensor mounting
Name: PAR 4/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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To eliminate the effect of the ever changing atmospheric pressure, a so-called relative sensor is
used. For this type of sensor the front side is exposed to the tank pressure whereas the backside is
exposed to the atmospheric pressure. As a result only the difference between tank pressure and
atmoshperic pressure – what is proportional to the fill level - deflects the sensing element
SUHVVXUH
VHQVLQJ
HOHPHQW
SDWP
S
Sensing Element
The sensing element itself usually needs to be protected from aggressive, corrosive or conductive
media. This can be achieved with a metal diaphragm foil that separates the measured media from
the sensor, but does not influence the pressure.
A pressure transmitting fluid behind the diaphragm assures that the outer pressure is applied to the
sensing element.
Sensing Element Inside Sensor
Name: PAR 5/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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As described above a relative sensor needs a connection to the atmospheric pressure. For a
submersed pressure sensor this connection can only be done thru the cable. The backside of
the sensing element is connected to the cable what established a pressure connection to the
HNA connecting box. A ventilation element at the lower side vents the HNA box and
establishes the pressure connection between atmoshere and the backside of the pressure
sensing element.
Ventilation Principe
Name: PAR 6/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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2 Components Of The Sensor System
The pressure sensor system consist of 4 main parts (only for KS) connected with an isolated 5
core cable.
Types 3 different types of sensors are in use:
- KS-Sensor for inside tank applications, clamp- or pipe mounting
- FW-Sensor with flange adaptor acc. to DIN EN 1092-1 form B1
- GW-Sensor with screw adaptor connection G 1“
Tank Top Flange (only for KS installation).
Ventilated HNA connection box.
Sensor cable in various lengths.
Sensor Types Tank Top Flange HNA Connection Box
Sensor Cable
Name: PAR 7/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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Storage – Transport- Handling
Handle the sensor carefully, the sensor is a very precise and sensitive
measuring device!
Store and transport these devices only under clean and dry conditions!
Avoid exposure to shocks and excessive vibrations!
Protect the sensor connector as well as the cable ends from any
humidity!
Do not remove the device or the cable from its packaging unless
required for installation!
The sensor sockets are protected by a red screw cap and the membrane
by a red cover. The cable plug is protected by a black cap.
Do not remove the protective caps prior to installation!
Cable Plug Cover Red Socket And Membrane Covers
Name: PAR 8/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3 Installation
Do NOT touch the membrane
of the sensor.
This could cause a zero-shift of
the device or a permanent damage.
Assure that the correct sensor will be mounted in the corresponding tank, please compare the label
on sensor.
Sensor Types with Tank Labels
Name: PAR 9/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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While you handle the sensor cable take care for proper hose bending and avoid any buckling or
damaging of the protection/ventilation hose.
The free space between cable and hose is necessary for atmospheric pressure compensation
Between ventilated HNA connection box and sensor.
Sensor Cable With Protection Hose
Name: PAR 10/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3.1 Sensor Connection
Check socket and plug for traces of humidity, dirt and mechanical damage. The pictures below
show how sensor socket and cable plug look when shipped.
Cable Plug
Sensor Socket
Due to the twist-protection nose there is only one possible orientation of cable plug and sensor.
Watch the twist-protection when plugging the cable into the sensor connector. Do not apply
excessive force when plugging in the cable.
Cable plugged into sensor, cap nut open
Name: PAR 11/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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Now screw in the cap nut by hand. Turn only the nut. Do not turn the sensor or the cable. Finally
tighten the connection with an open end wrench. Hold the sensor and the cable with one hand and
the wrench with the other hand. The O-ring at the bottom of the sensor connector must be fully
covered by the cap nut when done correctly
Correct Installed Sensor Nut
Tightening The Cable Nut
Turn nut only!
Don’t turn the sensor!
Don’t turn the cable!
Name: PAR 12/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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Sensor Installation Instructions 1.0 15.07.14
3.2 KS Sensor Type Installation
KS Sensor Type will be installed inside the tank. Take care about the distance between sensor and
heating elements. Too near installation of sensor clamp or sensor pipe to the heating coils could
damage the sensor irreparable.
3.2.1 Mounting the tank top flange
When the sensor will be drove through a tank flange, it is necessary to install a seal between the
two flanges.
When the sensor will be exchanged, please check the seal
Bottom Flange, welded thru the vessel Upper Flange
Name: PAR 13/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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To pass the tank top flange with the sensor cable an 8mm-1/4” gland with PTFE seal is used.
Check that the gland is screwed correctly, and take care that the black seal is not damaged, or
arched outwards.
Drive the open end of the cable through the tank top flange via the gland and tighten the nut.
Tank Top Cable Gland Tank Top Cable Gland Tightend
Name: PAR 14/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3.2.2 KS Sensor Mounted Via Clamp
Install the KS-Sensor with a clamp inside the tank (DRAWING 1)
KS Sensor Clamp Installation
Name: PAR 15/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3.2.3 KS-Sensor Mounted Inside Pipe
Install the KS-sensor in a pipe, by let down the sensor till the end. (DRAWING 2) (DRAWING 3)
KS Sensor Pipe Installation KS Sensor Pipe Installation, Stop Bolt
Name: PAR 16/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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Typical errors
If the pipe is not mounted in one piece, you must take care of the alignment of the pipe.
The sensor could stuck inside the pipe before he reached the stop bold.
If the sensor cable is too short it may happen that the sensor doesn’t reach the end of the pipe.
Please crosscheck the Tank Sensor List for original assigned cable length. If the cable length
inside the Tank Sensor List doesn’t fit to the necessary length please inform Hoppe for updating
the list and use/order the necessary cable length.
KS sensor pipe bad alignment KS Sensor cable too short
Name: PAR 17/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3.3 GW Sensor Type Installation
The Connection adapter of the GW sensor type is equipped with a G1” thread.
It is typically installed via a ball valve with flange.
By installing a GW-Sensor, make sure that a copper sealing ring is used between the valve and
sensor. (DRAWING 4)
By sensor exchange, please check the copper ring for damage and replace it when necessary.
G1” Ball Valve with Copper Ring Installed GW Sensor with Ball Valve
Name: PAR 18/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3.4 FW Sensor Type Installation
By installing a FW-Sensor, make sure that sealing packing is used between the valve and sensor.
In case of sensor exchange, please check packing for damage and replace it when necessary
(DRAWING 6) (DRAWING 7)
FW Seal Installed
FW Seal Installed FW
Sensor
Name: PAR 19/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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3.5 Cable guidance
Before the cable will be drove into the HNA connection box, please lay down one loop with
a minimum radius of 45mm, over the HNA box and fix it with cable straps
Cable Loop
Name: PAR 20/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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4 Mounting the HNA connection box
The HNA connection box must always mounted vertical in dry area. Ensure that the HNA
connection box air ventilation with sinter filter shows downwards, to avoid drip water
ingress. (PICT. 1)
Wet area could damage the sensor
5 Insert the cable into the HNA connection box
Insert the cable into the HNA connection box using the screw connection with PTFE-seal.
Tighten the nut.(PICT. 2)
6 Check sinter filter
Please check wether the HNA connection box has sintered filter..(PICT. 3)
PICT. 1 PICT. 2 PICT. 3
Name: PAR 21/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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7 Connect sensor cable (Sensor site)
Connect the sensor cable as per table.(PICT. 4) The shield-wire must by protected by a
shrink tube or adhesive tape.
Reference Table Sensor Typ HCG 2011
Typ Colour Pin
Supply 24V (+) brown 1
Supply 0V (-) green 2
Earth yellow 7
Shield 7
Option: white 4
Resistance therm. PT 100 grey 5
PICT. 4
Name: PAR 22/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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8 Connect sensor cable (Ship site)
Connect the ship cable as per table.(PICT. 5) The shield-wire must by protected by a shrink
tube or adhesive tape and the earth wire has to be connected to the ground screw (PICT.
6)
Reference Table Sensor Typ HCG 2011
Typ Colour Pin
Supply 24V (+) 1
Supply 0V (-) 2
Earth green/yellow 7
Shield Shrink tube 7
Option: 4
Resistance therm. PT 100 5
PICT. 5 PICT. 6
Name: PAR 23/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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9 Close the HNA connection box (PICT. 7)
PICT. 7
Name: PAR 24/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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Sensor typical installation drawing
KS-Sensor clamp installation
DRAWING 1
Name: PAR 25/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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KS-Sensor pipe installation
For the installation in a pipe, it’s very important that the sensor lowered down until
the bottom of the pipe.
DRAWING 2
Name: PAR 26/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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KS-Sensor pipe installation
For the installation in a pipe, it’s very important that the sensor lowered down until
the bottom of the pipe.
DRAWING 3
Name: PAR 27/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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GW-Sensor tank measuring
DRAWING 4
Name: PAR 28/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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FW-Sensor tank measuring
DRAWING 5
Name: PAR 29/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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FW-Sensor draught measuring
DRAWING 6
Name: PAR 30/31
Date: 15.07.14
Hoppe Bordmesstechnik GmbH
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GW-Sensor draught measuring
DRAWING 7
Name: PAR 31/31
Date: 15.07.14