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Online Electronics 4003 MAGSIG, Operating Manual

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Online Electronics Limited

 

+ 44 (0) 1224 714714 

[email protected]

online-electronics.com

CHALLENGE

 

ACCEPTED

Non-Intrusive Pig Signaller 

Magnetic Topside

Operating Manual

The 4003 MAGSIG® is a fully ATEX, IECEx 

and CSA/cUL certified, non-intrusive

pig signaller which quickly and

accurately detects, signals and logs the 

passage of magnetic pigs at critical points

along a pipeline both on land and offshore

Summary of Contents for 4003 MAGSIG

Page 1: ... ACCEPTED Non Intrusive Pig Signaller Magnetic Topside Operating Manual The 4003 MAGSIG is a fully ATEX IECEx and CSA cUL certified non intrusive pig signaller which quickly and accurately detects signals and logs the passage of magnetic pigs at critical points along a pipeline both on land and offshore ...

Page 2: ...TEGRATION added C00 05 11 19 MJ CR00525 Updated for change in detection algorithm event logging to EEPROM and event and data logging to SD card C01 10 03 20 MJ CR00525 Updated Modbus table with new entries C02 06 04 20 MJ CR00893 Added words to ensure the control button is pressed firmly C03 16 04 20 MJ CR00893 Additional changes after review Firmware RevC C04 20 04 20 MJ CR00893 Further minor cha...

Page 3: ... 5 10 DETECTION DELAY 14 4 5 11 DETECTION METHOD 14 4 5 12 AUTO POWER OFF 15 4 5 13 RELAY LOGIC 15 4 5 14 SENSOR SELECT 15 4 5 15 SENSOR OUTPUT 15 4 5 16 LED FLASH 15 4 5 17 BLUETOOTH 16 4 5 18 INTERFACE 16 4 5 19 RS485 BAUD RATE 16 4 5 20 RS485 PARITY 16 4 5 21 MODBUS ADDRESS 16 4 5 22 SD LOG 16 4 5 23 LANGUAGE 16 4 5 24 RESET TO FACTORY SETTINGS 16 4 5 25 EXIT MENU 17 4 6 MODBUS RTU RS485 INTERF...

Page 4: ... ENABLE 29 5 2 BLUETOOTH CONNECTION 29 5 3 DEVICE DISPLAY INFORMATION 31 5 3 1 DEVICE CHANGEABLE FIELDS 31 5 3 2 INDICATION ONLY 31 5 3 3 LOGGED DATA 31 6 ROUTINE MAINTENANCE AND STORAGE 32 7 DISPOSAL 32 8 WARRANTY 32 9 SAFETY INSTRUCTIONS 33 ...

Page 5: ...ickness and the quality of magnets fitted For optimum performance it is recommended that pigs are fitted with magnets as described in section 4 14 RECOMMENDED MAGNET ARRANGEMENT POWER OPTIONS The unit can be powered from internal batteries or from an external 24Vdc supply Batteries can be fitted to provide backup power should the external supply fail The unit uses either 4 off individual D sized c...

Page 6: ...X IECEx code Refer to Section 9 SAFETY INSTRUCTIONS EC Type Examination Certificate Number SIRA18ATEX1244X IECEx Certificate Number SIR 18 0059X CSA CSA US CSA18CA70166719 Weight in Aluminium 3 5kg 8lbs Weight in Stainless Steel 5 5kg 12lbs Note 1 In Listening Low Power Mode at 20 C with Bluetooth LED s disabled Dependent on initial battery capacity 2 2 STANDARD OUTPUTS DPDT Relay Output Volt Free...

Page 7: ...e training and competence of operators and the manner in which it is used This manual should be read through and understood before installation and commissioning so that the operator is familiar with the equipment Contact Online Electronics Ltd immediately should any difficulty arise in the use of this equipment CAUTION If the unit is to be placed in storage always ensure that it is turned OFF and...

Page 8: ...ows the current date and time If the date and time has not been set or the RTC backup has expired an error message will be displayed to indicate that the date and time require setting by the user The next screen shows the status of the AUTO POWER OFF feature See section 4 5 12 AUTO POWER OFF for more information The next screen shows the detection method selected Reference section 4 5 11 DETECTION...

Page 9: ...red The example shown is EVENT 12 which occurred on 01 21 18 at 13 43 in MM DD YY HH MM format The live DIFFERENCE flux reading D 0002 is also displayed In a magnetically quiet environment this number can be expected to flicker between 0000 and 0005 After displaying the LIVE DATA screen for 10 seconds the display will be switched off as shown opposite While LISTENING the LEDs around the display wi...

Page 10: ...lash every 1 second and the relay and current loop outputs will be in the DETECTION state the unit will keep logging until its internal buffer is full or the CONTROL BUTTON is firmly pressed the event will then be logged If DETECTION starts and the pig does not pass the signaller the signaller will timeout after 3 minutes and 20 seconds the signaller and will return to LISTENING no DETECTION delay...

Page 11: ...will not detect the same pig twice but will enter LISTENING mode in time to detect the next pig The unit can log up to 100 events with date time and the peak DIFFERENCE flux reading Once 100 events have been logged the screen opposite will be displayed indicating that the logger memory is full Subsequent events will be signalled but no data will be logged If an SD card is installed and Logging is ...

Page 12: ...re several parameters which are discussed in this section The menu interface is navigated using the control button A firm momentary button press 2 second cycles through the menu items and a long button press 3 seconds selects the current menu item If the control button is not pressed for 30 seconds or if the user selects the EXIT MENU option the unit will return to LISTENING mode LISTENING BLANK S...

Page 13: ... to memory Once the button has been pressed long enough to save the value a will be displayed in the bottom left corner of the screen to indicate that the button may now be released The display will now return to the main menu When a menu item that performs an action such as view events is selected a will be displayed in the bottom left corner of the display to indicate that the item has been sele...

Page 14: ...he CONTROL BUTTON Each event written will be in Comma Separated Values csv format which can be read by most spreadsheet applications The filename format of YYMMDD HHMMSS EVENT XXX LOG csv where YYMMDD is the date HHMMSS is the time and XXX is the event number Each log file will consist of Event No XXX Threshold Time DD MM YY HH MM SS Detection Time DD MM YY HH MM SS Peak Difference 3699mG Peak Raw...

Page 15: ...icant power from the batteries which will reduce the battery life of the unit In LOW POWER MODE the display will turn OFF after 10 seconds to preserve the battery life The detection routines are identical in each mode 4 5 9 STABILISATION DELAY Selecting this item allows the STABILISATION delay to be configured It is possible to configure any value between 00 00 00 and 99 59 59 in HH MM SS format R...

Page 16: ...N state the Normally Closed contacts of the relays will be open and the Normally Open contacts will be connected to their respective Common contacts If RELAY LOGIC is configured as INVERTED then then while in the LISTENING state the Normally Closed contacts of the relays will be open and the Normally Open contacts will be connected to their respective Common contacts While in the DETECTION state t...

Page 17: ...m configures the type parity check for the serial interface Either EVEN PARITY required by MODBUS protocol or NO PARITY can be selected In total 11 bits are transmitted per character START 8 BIT DATA PARITY STOP BIT 4 5 21 MODBUS ADDRESS Selecting this item configures the MODBUS slave address for the unit Valid addresses are from 1 to 247 4 5 22 SD LOG Selecting this item allows the SD Logging fea...

Page 18: ...cessor handles current loop signalling and MODBUS communications The two units are electrically isolated from each other so that the communication interface can be isolated from the housing earth connection The electrical ground connection for the Main Processor is connected to the housing earth due to the use of Zener Barrier type circuits inside the 4003 as required by hazardous area certificati...

Page 19: ...OLD INPUT REGISTERS 30000 Serial Number Serial number of unit 30001 DOMyy Year of manufacture 30002 DOMmm Month of manufacture 30003 FWRevMajor Software Revision Number 30004 FWRevMinor Software Revision Number 30005 Number of events Current number of events 30006 Event Date DD Selected event date day 30007 Event Date MM Selected event date month 30008 Event Date YY Selected event date year 30009 ...

Page 20: ...4003_5001_D02 Page 19 of 35 40018 Sensor Output 40019 Status OEL Use Only 40020 Detection Type 0 Peak Value 50 1 Peak Value 25 2 Peak Value 10 3 Peak Value 5 4 Detection Only Reference section 4 5 11 ...

Page 21: ... 22 SD LOG at a rate of one record entry every 200ms The data log file will be automatically created on power up and closed on shutdown The filename format is YYMMDD HHMMSS 4003 LOG csv The date and time is the point the file was created Detection Log A DETECTION log file is created with each EVENT occurrence The event file is similar to the EVENT LOG The detection log is created if the SD Card is...

Page 22: ...r Safe Use detailed in Section 9 SAFETY INSTRUCTIONS of this manual must be observed at all times 2 Ensure the mounting plate is securely fitted to the housing 3 Temporarily place the unit at the chosen location to ensure that the unit sits in place without rocking 4 Loop the band through the slots provided as shown and then gradually tighten the band until the unit is held firmly Do not use exces...

Page 23: ...AL AND ARE ALL OF THE SAME TYPE ALWAYS OBSERVE CORRECT BATTERY POLARITY 4 off D cell alkaline 4 off D cell NiMh 2 off D cell Lithium Dummy cells or barriers will be fitted in the spare vacant cell compartment These should not be removed Confirming that the polarity of the batteries matches that indicated by the markings within the battery compartment The negative end of each battery should be in c...

Page 24: ...equired to intrinsic safe equipment using the relay contacts covers will be provided at the time of manufacture for RLY1 RLY2 connection blocks When a remote sensor is fitted a cover will be fitted at manufacture over the sensor connection block and should not be removed Connections are clearly labelled on the PCB and have the following functions NC Normally Closed contact of relay pole 1 and 2 CO...

Page 25: ...n and the Normally Open contacts will be connected to their respective Common contacts 4 10 2 CURRENT LOOP OUTPUT The current loop connections are non polarised Ensure that 21 6Vdc to 26 4Vdc is maintained at the unit connections When the unit is set for CURRENT LOOP refer to Section 4 5 18 INTERFACE The unit will consume 16 0mA 1 0mA when in the LISTENING state refer to Section 4 3 LISTENING The ...

Page 26: ...e applied voltage I P V Typically a 5W heater is fitted so current 5 24 0 2A A supply capable of providing at least this current will be necessary to operate the heater correctly 4 12 RTC BACKUP The unit includes RTC backup to retain the date time If the unit is turned off but the main batteries or the external power is left connected then memory backup will retain these settings indefinitely If t...

Page 27: ...etection countdown refer to Section 4 4 3 DETECTION DELAY Upon PIG DETECTION refer to Section 4 4 1 PIG PASSED a message is transmitted via the LoRa radio to the Online Electronics LoRa Base Station which outputs the following on its USB virtual COM PORT in CSV format 4003 NNNNN S PPPPP EEE BBB RRR VV CR Where NNNNN is five digit serial number of the 4003 transmitting the message S is the pole det...

Page 28: ...Bm and SNR of 6 4003 00346 S 00101 001 4 2 48 7 CR Indicating 4003 serial number 346 south pole detected peak flux at detection of 101mG event number 1 battery voltage of 4003 is 4 2V Rssi of 48dBm and SNR of 7 An optional verbose mode is available on the Online Electronics LoRa Base Station which outputs a serial string with the same information but in a human readable format The final ACK sent s...

Page 29: ...ger the magnetic signal PIPELINE MATERIAL Different materials cause different attenuations to the magnetic signals For example 50mm of concrete will affect the signal considerably less than 50mm of mild steel DISTANCE BETWEEN MAGNET AND SENSOR The closer the magnets are to the magnetic sensor the stronger the magnetic signal NUMBER OF MAGNETS FITTED TO PIG The more magnets which are placed around ...

Page 30: ...TH CONNECTION When the blue light is flashing on the 4003 approximately one flash every 2 seconds enable the Online Icon for the 4003 Bluetooth communication feature on your device and stand within 3 to 4 feet of the front glass of the unit with your handheld pointing at the glass window Tap SCAN it should make connection with the unit the blue light will begin flashing 2 times with a 1 second tim...

Page 31: ...4003_5001_D02 Page 30 of 35 ...

Page 32: ... Tabular Entry 4 Stabilization Delay Tabular Entry 5 Detect Delay Tabular Entry 6 Low Power Mode Sliding switch 7 Relay Polarity Sliding switch 8 Remote Sensor Sliding switch 9 SD Card Logging Sliding Switch 10 LED Flash Sliding Switch 11 Baud Rate Tabular Entry 12 Parity Tabular Entry 13 Slave ID Tabular Entry 14 Threshold Tabular Entry 5 3 2 INDICATION ONLY The following fields are indication on...

Page 33: ... for the proper treatment and recovery The crossed out bin symbol placed on the product reminds you of the need to dispose of it correctly at the end of its life When buying a new product you will have the possibility to return free of charge another end of life product of equivalent type that has fulfilled the same functions as the supplied equipment These items may be deposited at Online Electro...

Page 34: ...ed glands 8 The sensor cable length shall not exceed 20 meters 9 All wiring for external connections shall be made using suitable crimp ferrules to prevent accidental disconnection as per IEC60079 11 2011 Cl 6 2 2 10 When the relay is used for IS interface all relay contacts shall only be connected to intrinsically circuits Once the contacts are connected to any non IS circuits they are no longer ...

Page 35: ... 50 C 20 C to 50 C Lithium battery SAFT LS33600 40 C to 73 C 40 C to 80 C 40 C to 80 C NiMH battery ANSMANN 8500 20 C to 60 C 20 C to 60 C 20 C to 60 C With intrinsic interface to relay Temperature Class Power Supply T6 T5 T4 External supply 1W 40 C to 73 C NOTE 1 78 C 40 C to 82 C 40 C to 82 C External supply 5W 40 C to 70 C 40 C to 72 C 40 C to 72 C External supply 10W 40 C to 59 C 40 C to 59 C ...

Page 36: ...tion described above is in conformity with the relevant Union harmonisation legislation ATEX ATEX Directive 2014 34 EU IECEx IECEx System EMC EMC Directive 2014 30 EU The following harmonised standards and technical specifications have been applied ATEX EN 60079 0 2012 A11 2013 EN 60079 1 2014 EN 60079 11 2012 IECEx IEC 60079 0 2011 IEC 60079 1 2014 IEC 60079 11 2011 EMC EN 61000 6 4 2007 A1 2011 ...

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