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CDI CD52 Bandit, User Manual

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CD52 Bandit (ATEX-IECEx Certification) User Guide

Page 5 of 48

CONTENTS

INTRODUCTION

 ..................................................................................6

SETUP & OPERATION

 ..........................................................................7

  Power Options

 ....................................................................................7

  Power Configuration Chart

 .................................................................8

  Battery Installation

 .............................................................................9

  User Board Jumper Settings

 .............................................................10

  24 VDC & SCADA Connections

 ..........................................................12

  Detection Methods

 ...........................................................................16

  User Interface ...................................................................................19

INSTALLATION ...................................................................................28

  Standard and Stainless Steel Units ...................................................28

  Armored Flex Cable Units

 .................................................................

32

OPTIONAL EQUIPMENT

 ...................................................................

33

  Remote Indicator System (RIS) .........................................................

33

  Cathodic Protection Base Mounting 

 ................................................

33

  Heater ...............................................................................................

33

  Heat Risers ........................................................................................

33

  LineStat .............................................................................................

34

  Sunshade ..........................................................................................

34

 

WARRANTY ........................................................................................

35

SERVICE & MAINTENANCE

 ...............................................................

36

GENERAL ARRANGEMENT DRAWINGS

 ...........................................

37

SYSTEM SPECIFICATIONS

 .................................................................45

PIG MAGNET MOUNTING

 ................................................................47

ABOUT CDI

 ........................................................................................48

Summary of Contents for CD52 Bandit

Page 1: ...801 North Juniper Avenue Broken Arrow Oklahoma 74012 U S A 1 918 258 6068 worldwide www pigging com support pigging com CD52 Bandit Non Intrusive Pig Passage Signaler ATEX IECEx Certification USER GUIDE ...

Page 2: ...nd firmware described in this document are designed manufactured and written by CDI The software and firmware 1999 2010 CDI with all rights reserved The CD52 product is covered under United States Patent No 6 489 771 B1 The TRAXALL family of transmitters is covered under United States Patent No 9172406 This document 1999 2017 CDI All rights reserved Document Number 89 03 0066 00 Revision 24 July 2...

Page 3: ... in this manual The purchaser of this equipment is responsible for the training and competence of operators and the manner in which it is used Contact CDI immediately should any difficulty arise in the use of this equipment WARNING Always use caution when opening any CDI transmitter that has been in a pressurized environment It is possible for pressurized liquid or gas to leak into a transmitter a...

Page 4: ...CD52 Bandit ATEX IECEx Certification User Guide Page 4 of 48 ...

Page 5: ...SCADA Connections 12 Detection Methods 16 User Interface 19 INSTALLATION 28 Standard and Stainless Steel Units 28 Armored Flex Cable Units 32 OPTIONAL EQUIPMENT 33 Remote Indicator System RIS 33 Cathodic Protection Base Mounting 33 Heater 33 Heat Risers 33 LineStat 34 Sunshade 34 WARRANTY 35 SERVICE MAINTENANCE 36 GENERAL ARRANGEMENT DRAWINGS 37 SYSTEM SPECIFICATIONS 45 PIG MAGNET MOUNTING 47 ABOU...

Page 6: ...na array signals an on board computer if and when a pig passage has occurred When a pig passage is detected the time and date of passage are recorded into the on board memory of the Bandit and displayed on an LCD screen In addition to the most recent pig passage time and date the Bandit remembers the dates and times of the previous nine pig passages as well An operator may quickly and easily retri...

Page 7: ...r Configuration chart on the following page to determine which power option is required for your conditions WARNING Always remove batteries before placing the unit into storage and or configuring for 24 VDC operation Failure to do so may result in damage and may void warranty NOTE If using batteries as a power source DURACELL PROCELL PC1300 D Cell alkaline batteries are required by ATEX and or IEC...

Page 8: ...CD52 Bandit ATEX IECEx Certification User Guide Page 8 of 48 SETUP OPERATION Power Configuration Green indicates ATEX IECEx certified temperature range ...

Page 9: ...install D cell batteries 1 Unscrew and carefully remove front cover 2 If old batteries are in place pull cable tie release tab use small screwdriver or fingernail to disengage cable tie 3 Insert new alkaline batteries both with positive side up NOTE The battery cable ties are releasable Do not cut them ...

Page 10: ...ecification at time of order If power source is to be changed for example if your CD52 was ordered and shipped as a 24 VDC powered unit and you desire instead to operate it with batteries you must re set the jumper as shown Board Settings for Battery Power Set jumper to Pin 1 NOTE Set jumper before installing batteries 4 20mA Current Loop Interface models are pre set for 24 VDC power and cannot be...

Page 11: ...Tamb 40 C 45 C BATTERY OPERATION WARNING USE ONLY DURACELL PC1300 BATTERIES WARNING DO NOT MIX OLD WITH NEW BATTERIES WARNING DO NOT OPEN WHEN ENERGIZED WARNING EXPLOSION HAZARD BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON HAZARDOUS WARNING BATTERY OPERATION ONLY ALLOWED TO MAXIMUM 45 C WARNING DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE IS PRESENT Replace front cover ...

Page 12: ...ing through separate conduits To route 24 VDC and SCADA into the Bandit unit 1 Standard Unit Remove threaded outlet plug s from the Killark junction box as shown SCADA Supervisory Control and Data Acquisition compatible standard relay contacts can be used for passage annunciation lights horns etc where an unmanned passage must be monitored SCADA compatible 4 20mA option allows connection to plant ...

Page 13: ...uld have an assembled and fully functional CD52 Bandit system A system wired in this manner is capable of running on 24 VDC allowable range 21 6 to 26 4 VDC and indicating a passage to the SCADA system via relay closure or via 4 20mA Current Loop NOTE Once Killark outlet plugs have been removed and wiring installed is critical that the outlets be resealed properly to maintain ATEX standards This c...

Page 14: ...ELLOW WIRE WHITE WIRE COMMON NORMALLY OPEN NORMALLY CLOSED INSTALL SITE POWER 24VDC INSTALL SITE POWER 0VDC CDI USE ONLY CUSTOMER CONNECTIONS DO NOT CONNECT COMMON TO 0VDC TERMINALS CDI CONNECTIONS OUTLET BODY SHOWN WITH COVER REMOVED 24V VOLTAGE REQUIREMENTS 21 6 VDC MINIMUM 26 4 VDC MAXIMUM MEASURED AT CD52 TERMINAL BLOCK STANDARD 0 48 WATTS HEATER OPTION 12 WATTS INTERMITTENT RIS OPTION 8 4 WAT...

Page 15: ...DO NOT CONNECT COMMON TO 0VDC TERMINALS CDI CONNECTIONS OUTLET BODY SHOWN WITH COVER REMOVED 24V VOLTAGE REQUIREMENTS 21 6 VDC MINIMUM 26 4 VDC MAXIMUM MEASURED AT CD52 TERMINAL BLOCK STANDARD WITH 4 20mA OPTION 1 6 WATTS HEATER OPTION 12 WATTS INTERMITTENT RIS OPTION 8 4 WATTS POWER REQUIREMENTS 1 NOTES 1 WHEN PIG IS NOT DETECTED OUTPUT SHALL BE 4mA 2 WHEN PIG IS DETECTED OUTPUT SHALL BE 20mA 3 B...

Page 16: ...ASSEMBLY B SCALE B SIZE REV PERMANENT MAGNET ASSORTMENT DWG NO SHT REVISIONS REV DESCRIPTION DATE APPROVAL ENGR 1 PART NO NOTED RareEarth SET 2004 N A FILE 2 TOLERANCE XXX 015 XX 03 X 06 ANGLE REVISED M1 M2 M3 A F WHITE 2 17 00 10 21 04 CHANGED DIA DIM 1 345 WAS 1 315 F WHITE ADDED DECAL WITH PART NUMBER B 34 93 1 375 4 MOUNTING STUDS ARE STAINLESS STEEL CD52 M2 MAGNET 6 250 158 75 33 66 1 325 14 ...

Page 17: ...ed option Electromagnetic Transmitters The CD52 Bandit detects active electromagnetic transmitters CDI offers the largest family of pipeline pig location and tracking transmitters in the industry Our Transmitters operate by emitting electromagnetic fields at a very low frequency between 15 and 30 Hz This makes CDI s pig tracking transmitters safe and reliable for use in any onshore or offshore env...

Page 18: ...ng and pinpointing CDI X Series electromagnetic transmitters pigging industry standard 22 Hz Legacy transmitters and magnetic flux leakage MFL pigs It is possible to use both a permanent magnet and a transmitter in the same pig This will not prevent the Bandit TRAXALL or CD42 Receiver systems from successfully tracking and locating pigs Regardless of which type of transmission source you use the B...

Page 19: ...colon will blink momentarily appear and the TIME Active Function Indicator segment will display When the most recent pig passage time is displayed the colon display will be constant non blinking and the TIME Active Function Indicator segment will not display Passage Date Current Date These segments normally alternate between displaying the real time date and the date of the most recent pig passage...

Page 20: ... allows an operator to quickly determine how recently a pig has passed Therefore a constant on segment indicates a pig passage has occurred within the last 12 hours but more than one hour ago RECENT PASSAGE SEGMENT STATUS Displayed Passage Indicator The Displayed Passage Indicator is a cone shaped array of 10 segments Each one of these individual segments represents one of the 10 pig passage times...

Page 21: ...ments are reserved for future functions and or customer requested applications F1 Unit is in Suspend Mode F2 Unit is in Suspend Mode F3 Reserved F4 Reserved RELAY Internal contact relay engaged F6 Reserved F7 Reserved F8 Reserved TIME Real time currently displayed BTN User Interface Lever currently engaged Active Function Indicators The Active Function Indicators are an array of 10 rectangular LCD...

Page 22: ...operator will see two displays alternating every seven seconds as shown here MOST RECENT PIG PASSAGE MARKED REAL TIME DISPLAYED SECONDS 7 TIME INDICATOR MARKED SECONDS 7 Interface Lever The pivoting lever on the side of the unit has several functions Retrieving dates times of the last ten passages Clearing the recent passage indicator Set the real time clock The lever contains a small magnet that ...

Page 23: ...sition while unattended the unit will automatically override the lever setting after one minute and 45 seconds and automatically return to normal operation Real time Display The primary purpose of the real time display is to allow an operator to quickly and easily confirm the clock is set to the correct time See pg 26 for instructions on setting the clock The real time display has the following ch...

Page 24: ...h a unit and see the most recent passage data without interaction When displaying the time of the most recent passage the display will appear as shown MOST RECENT PIG PASSAGE TIME DISPLAY COLON STEADY DOES NOT BLINK ACTIVE FUNCTION INDICATORS UNMARKED Previous Pig Passages Use the Interface lever to review pig passage dates and times other than the most recent Simply rotate the bottom of the lever...

Page 25: ... AM on December 14th Repeatedly pressing and releasing the lever will toggle through the recorded pig passages and change the Displayed Passage Indicator segment to the corresponding indicator Moving to the oldest passage in memory requires a total of nine 9 lever activations after which the Displayed Passage Indicator segments loop back to the first passage To exit this mode and return to the nor...

Page 26: ...eared release the lever to return the unit to normal operation Removing the Recent Passage message from the screen will not affect anything in memory The most recent pig passage time and date will cycle every few seconds Setting the Clock Occasionally it will be necessary to set the unit s real time clock see note To do so hold the lever in the activate position for a period of eight 8 seconds Aft...

Page 27: ...t there You should notice the BTN segment lights and the hour digits begins to increase at a rate of one hour per second Continuing to hold the lever in the activated position will cause the hours to increase until they reach 12 and then wrap to 1 The Bandit uses 12 hour not 24 hour time Hold the lever in the activated position until the digit reaches the desired hour and then release The display ...

Page 28: ...t can be installed on pig launchers receivers and all pipelines from 50 8 mm to 1 524 mm 2 in to 60 in The Bandit s base is 508 mm 20 in long Make sure there is enough room on the pipe for installation To ensure unimpeded movement of the interface lever it is recommended the Bandit be mounted on a horizontal pipe NOTE To avoid inadvertent triggering of a false passage the portable Bandit should be...

Page 29: ...gh the slots at one end of the base Continue looping the free end around the pipe until it meets the buckle at the other end of the band Slide the free end of the band through the buckle NOTE The banding material and band tension tool are stocked by CDI NOTE The standard CD52 antenna base shown here is of cast aluminum and must be handled with care Do not over torque bands If needed use electrical...

Page 30: ... using the tension tool 4 Cut Excess Raise the tension tool to bend the band back over the buckle Pull the cutoff lever and cut off the excess banding material 5 Secure Buckle Secure the buckle Bend the end of the band down by lightly tapping with a hammer Using a hammer bend the two locking tabs over the end of the band NOTE Do not over torque bands on cast aluminum antenna base ...

Page 31: ...orientation for optimum viewing To do this loosen the union joint and adjust the Bandit face to the desired position Re tighten union joint If you have any difficulties or questions assembling and installing your Bandit system please feel free to contact CDI Telephone worldwide 1 918 258 6068 Email support pigging com NOTE Loosen union joint only enough to rotate Bandit Do not disassemble union ...

Page 32: ...nly 2 Remove antenna base unit strap using Phillips screw driver 3 Uncoil cable This requires two 2 personnel Person 1 will hold antenna base while supporting cable and walk in an ever widening circle While walking Person 1 will continually untwist the antenna base to prevent cable from kinking Person 2 will be responsible for uncoiling cable at the plastic spool 4 Startup procedure is identical t...

Page 33: ...ulation matting is available to protect pipeline coating Heater A 24 VDC internal heater is available and recommended for operation in temperatures below 30 C 22 F Heat Risers Heat riser insulators for the CD52 Bandit allow the system to be used on geothermal pipeline or other environments where pipeline surface temperatures exceed of 80 C 176 F NOTE Heat risers enable the CD52 Bandit to operate w...

Page 34: ... portable equipment Some of the details included in event notification messages are date time GPS position battery status and vibration This information is transmitted via satellite without use of cellular networks and without need of a wired infrastructure Sunshade The stainless steel sunshade can help protect the Bandit from intense sunlight by reducing overall temperature inside thus prolonging...

Page 35: ... representative sample thereof must be returned to CDI at the Purchaser s expense The goods must be accompanied by the Purchaser s written order describing the defect s and authorizing CDI to invoice the Purchaser for any charges not covered by the warranty Upon receipt of the equipment and Purchase Order CDI will examine the equipment and make a determination of the nature and cause of the defect...

Page 36: ...d by qualified personnel who are familiar with any and all manuals and procedures for said equipment s operation Operating equipment while in a damaged condition nullifies this warranty Service and Repairs Cost for repairs not covered by the warranty or carried out after the warranty period has expired will be charged at the current hourly or set service rate plus the cost of materials upon approv...

Page 37: ...NDUCTIVE ISOLATOR OPTIONAL NOTES 1 DIMENSIONS ARE IN INCHES AND MILLIMETERS 2 UNIT WEIGHT 28 LBS 13 KG REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 1 27 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CDI IS PROHIBITED PROPRIETARY AND CONFIDEN...

Page 38: ...1 DIMENSIONS ARE IN INCHES AND MILLIMETERS 2 UNIT WEIGHT 30 LBS 3 7 LBS PER FOOT OF EXTENSION 13 6 KG 5 4 KG PER METER OF EXTENSION REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 2 5 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CDI IS PROHIBI...

Page 39: ...ONS ARE IN INCHES AND MILLIMETERS 2 WEIGHT 25 LB 3 LB PER FOOT OF CABLE 11 KG 43 KG PER METER OF CABLE REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 1 29 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CDI IS PROHIBITED PROPRIETARY AND CONFIDEN...

Page 40: ...IMETERS 1 WEIGHT 21 LBS 9 5 KG 2 USES BATTERY POWER ONLY 3 REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 2 7 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CDI IS PROHIBITED PROPRIETARY AND CONFIDENTIAL NEXT ASSY USED ON APPLICATION DIMENSIONS...

Page 41: ...DUCTIVE ISOLATOR OPTIONAL CATHODIC PROTECTION BASE MOUNTING STANDARD BASE MOUNTING NOTES 1 DIMENSIONS ARE IN INCHES AND MILLIMETERS 2 WEIGHT 63 LBS 29 KG REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 1 20 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMI...

Page 42: ...BASE MOUNTING 316 SS ENCLOSURE SHOWN WITH COVER NOTES 1 DIMENSIONS ARE IN INCHES AND MILLIMETERS 2 WEIGHT 68 LBS 3 6 LBS PER FOOT OF EXTENSION 30 8 KG 5 6 KG PER METER OF EXTENSION REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 2 7 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE...

Page 43: ...ION BASE MOUNTING SUNSHADE OPTIONAL NOTES 1 DIMENSIONS ARE IN INCHES AND MILLIMETERS 2 WEIGHT 65 LBS 3 LB PER FOOT OF CABLE 29 5 KG 43 KG PER METER OF CABLE 3 ALSO AVAILABLE WITHOUT THE 316 SS ENCLOSURE REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 7 23 14 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION ...

Page 44: ...ILLIMETERS 2 WEIGHT 26 LBS 11 8 KG 3 USES BATTERY POWER ONLY REVISIONS REV DESCRIPTION DATE APPROVED A RELEASED 2 10 2014 DS D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CDI ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF CDI IS PROHIBITED PROPRIETARY AND CONFIDENTIAL NEXT ASSY USED ON APPLICATION DIMENSI...

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