CDI CD52 Bandit User manual

1801 North Juniper Avenue
Broken Arrow, Oklahoma 74012 U.S.A.
[phone] worldwide
www.pigging.com
[email protected]
CD52 Bandit
Non-Intrusive Pig Passage Signaler
(ATEX-IECEx Cercaon)
USER GUIDE

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 2 of 48
Informaon in this document is subject to change without noce and
applies only to the version of soware, hardware, or rmware described
on the tle page.
The soware, hardware, and rmware described in this document are
designed, manufactured and wrien by CDI. The soware and rmware
© 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 transmiers 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 2017
TAG FOR CD52 BANDIT 81-05-0080 (STANDARD)

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 3 of 48
WARNING
Any operaon involving work on pipelines containing gases or liquids
under pressure is potenally hazardous. It is necessary, therefore, to
follow correct procedures in the use of this equipment to maintain
a safe working environment.
No person should use this equipment unless fully aware of potenal
hazards of working with pressurized pipelines and trained in the
procedures stated 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 diculty arise
in the use of this equipment.
WARNING
Always use cauon when opening any CDI transmier
that has been in a pressurized environment.
It is possible for pressurized liquid or gas to leak into a transmier
and remain there even aer the transmier has been removed from
the pipeline.
Always point the transmier away from yourself or others when
opening a cover or end cap.
WARNING
Field repair of amepath-related components of these units
is not authorized

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 4 of 48

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 5 of 48
CONTENTS
INTRODUCTION ..................................................................................6
SETUP & OPERATION..........................................................................7
Power Opons ....................................................................................7
Power Conguraon Chart .................................................................8
Baery Installaon .............................................................................9
User Board Jumper Sengs .............................................................10
24 VDC & SCADA Connecons..........................................................12
Detecon 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 Protecon Base Mounng ................................................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

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
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INTRODUCTION
*Contact CDI for customer-specied length
**CD52 Portable models are baery powered only and have no juncon
***Oponal conguraon for SCADA network communicaon (see next page)
INTRODUCTION
The CD52 Bandit is a computerized electronic device for non-intrusive
detecon of pipeline pigs equipped with either a permanent magnet or
22 Hz electromagnec transmier.
The Bandit accomplishes this by a proprietary and patented magnec eld
antenna array located in its base and aached to (or near) the pipeline.
This antenna array signals an on-board computer if and when a pig
passage has occurred.
When a pig passage is detected, the me and date of passage are recorded
into the on-board memory of the Bandit and displayed on an LCD screen.
In addion to the most recent pig passage me and date, the Bandit
remembers the dates and mes of the previous nine pig passages as well.
An operator may quickly and easily retrieve the dates and mes of the 10
most recent pig passages via the Bandit’s user interface.
The CD52 Bandit is available in several conguraons:
• Rigid stalk extension-mounted (“standard”)
• Extended ex-cable*
• Extended pipe*
• Portable**
• Stainless steel enclosed, ex-cable, extended-pipe, and portable
• 4-20mA Current Loop Interface***
24 VDC,
SCADA JUNCTION,
& 4-20mA OUTPUT
COMPUTER
& DISPLAY
BASE &
ANTENNA
STANDARD

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
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SETUP & OPERATION
SETUP & OPERATION
Power Opons
The Bandit in its standard conguraon can be powered for one year
on two new D-Cell alkaline baeries (see notes). However, many
customers choose to power the Bandit by supplying 24 VDC power.
In extreme cold temperatures, 24 VDC will be necessary to power the
Bandit as a small heang element opon (see pg. 33) is required.
Also, ATEX/IECEx guidelines require use of external 24 VDC power where
temperatures exceed +45°C.
See the Power Conguraon chart on the following page to determine
which power opon is required for your condions.
WARNING:
Always remove baeries before placing the unit into storage
and/or conguring for 24 VDC operaon. Failure to do so
may result in damage and may void warranty.
NOTE: If using baeries as a power source,
DURACELL® PROCELL (PC1300) D-Cell
alkaline baeries are required by ATEX and/or
IECEx standards to maintain system cercaon.
NOTE: Bandits with oponal 4-20mA Current Loop Interface
conguraon require 24 VDC power.
They cannot be powered by baeries.
EXTENDED PIPE
FLEX CABLE FLEX CABLE
w/STAINLESS
BASE
ENCLOSED
w/EXTENDED PIPE
PORTABLE
316 STAINLESS STEEL ENCLOSED
PORTABLE
w/STAINLESS
BASE
ENCLOSED
w/FLEX CABLE

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
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SETUP & OPERATION
Power Conguraon
Green indicates ATEX–IECEx cered temperature range

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
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SETUP & OPERATION
Baery Installaon
To install D-cell baeries:
1. Unscrew and carefully remove front cover
2. If old baeries are in place, pull cable-e release tab (use small
screwdriver or ngernail) to disengage cable-e.
3. Insert new alkaline baeries,
both with posive (+) side up.
NOTE: The baery cable es are releasable. Do not cut them.

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 10 of 48
SETUP & OPERATION
User Board Jumper Sengs
The CD52 Bandit user board contains a jumper block which has
been factory set for baery or 24 VDC power source, depending on
specicaon at me 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 baeries), you must re-set the
jumper as shown:*
Board Sengs for Baery Power
Set jumper to Pin 1.
NOTE: Set jumper before installing baeries.
*4-20mA Current Loop Interface models are pre-set for 24 VDC power and
cannot be recongured for baery operaon.

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 11 of 48
SETUP & OPERATION
Board Sengs for 24 VDC Power
Set jumper to Pin 2.
ATEX/IECEx WARNINGS
Tamb = –40°C ~ +70°C (24 VDC OPERATION)
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.

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 12 of 48
SETUP & OPERATION
24 VDC & SCADA Connecons
It is the customer’s responsibility to provide their own wiring and conduit
for 24 VDC power and SCADA.* CDI recommends roung 24 VDC and
SCADA wiring through separate conduits. To route 24 VDC and SCADA into
the Bandit unit:
1. Standard Unit: Remove threaded
outlet plug(s) from the Killark juncon
box as shown.
* SCADA (Supervisory Control and Data Acquision) compable standard relay
contacts can be used for passage annunciaon (lights, horns, etc.) where an
unmanned passage must be monitored. SCADA-compable 4-20mA opon allows
connecon to plant automaon equipment using current loop interfacing.

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
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SETUP & OPERATION
Enclosed Unit: Remove plasc plug(s)* from boom of enclosure.
* Older units may have threaded steel plugs
and/or built-in conduit leading to the Killark box.
2. Remove the juncon box faceplate, feed the wiring through the conduit
or cable and using the wiring diagram on the following page, secure the
wires to the proper terminals.
3. Replace the juncon box cover and
secure hand-ght.
At this point, with correct electrical
connecons, you should have an
assembled and fully-funconal 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 indicang 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 crical that the outlets be resealed properly to maintain
ATEX standards. This can be done with pipe dope or pipe sealant and proper
conduit or ex cable.
It is the customer’s responsibility to ensure that all conduit connecons
are made and sealed according to ATEX and/or IECEx standards to maintain
system cercaon. Do not ghten conduit connecons and/or plugs beyond
20.33 N·m [15  lbf].

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
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SETUP & OPERATION
FOR BATTERY
OPERATION,
PLACE JUMPER
HERE
FOR 24V OPERATION,
PLACE JUMPER HERE
P1
DETAIL 'A'
OFF
+5
+3.3
BATT
It is the responsibility of the customer to
make these connections properly whatever
pipe or conduit is chosen for the job.
1. Remove a plug in the side of the outlet body for insertion of customer wiring. 2. Remove the lid of the outlet body. 3. Install the customer provided conduit and wiring. For wiring, strip off wire insulation to expose 5/16" length of wire. Insert a small diameter screw driver (or similar tool) into a square opening and depress the tab. This will open the adjacent round terminal. Insert the exposed wire into the terminal until it stops, then remove the tool from the square opening to secure the wire. 4. Reassemble the lid with the outlet body.
ATEX BANDIT WIRING/
INSTALLATION INSTRUCTIONS
5. Open Bandit enclosure and move jumper on PCB as shown in Detail 'A'. 6. Replace Bandit enclosure.
If 24V Connections were used,
complete steps 5 & 6
BLACK WIRE BROWN WIRE RED WIRE YELLOW 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 WATTS
POWER REQUIREMENTS
REVISIONS
REV.
DESCRIPTION
DATE
APPROVED
A
RELEASED
6/26/2012
DS
B
REVISED PER ECR 11251301; REPLACED OUTLET BODY; REVISED NOTES & TITLE TO INCLUDE ALL ATEX BANDITS
1/23/2014
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 ARE IN INCHES TOLERANCES: FRACTIONAL
1/32
ANGULAR:
2
TWO PLACE DECIMAL
.03
THREE PLACE DECIMAL
.010
MATERIAL
FINISH
DRAWN
CHECKED
ENG APPR.
MFG APPR.
Q.A.
COMMENTS:
DATE
NAME
TITLE:
SIZE
B
DWG. NO.
REV
WEIGHT:
SCALE:
UNLESS OTHERWISE SPECIFIED:
B
WIRING INSTRUCTIONS,
CD52 ATEX BANDIT
SHEET 1 OF 1
89-03-0062-00
DO NOT SCALE DRAWING
INTERPRET GEOMETRIC TOLERANCING PER: ASME Y14.5M - 1994
DS
9/23/2008
ECN #:

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 15 of 48
SETUP & OPERATION
It is the responsibility of the customer to
make these connections properly whatever
pipe or conduit is chosen for the job.
1. Remove a plug in the side of the outlet body for insertion of customer wiring. 2. Remove the lid of the outlet body. 3. Install the customer provided conduit and wiring. For wiring, strip off wire insulation to expose 5/16" length of wire. Insert a small diameter screw driver (or similar tool) into a square opening and depress the tab. This will open the adjacent round terminal. Insert the exposed wire into the terminal until it stops, then remove the tool from the square opening to secure the wire. 4. Reassemble the lid with the outlet body.
ATEX BANDIT WIRING/
INSTALLATION INSTRUCTIONS
BLACK WIRE BROWN WIRE RED WIRE YELLOW WIRE
WHITE WIRE
NOT USED
-ve (4-20mA LOOP INPUT)
+ve (4-20mA LOOP INPUT)
INSTALL SITE POWER +24VDC
INSTALL SITE POWER 0VDC
CDI USE ONLY
2345678910
TERMINAL NUMBERS
CUSTOMER
CONNECTIONS
MAXIMUM WIRE SIZE: Diameter = 1.78mm,
Cross-Section Area = 2.5mm²
(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. BATTERY OPERATION NOT AVAILABLE WITH 4-20mA OPTION.
REVISIONS
REV.
DESCRIPTION
DATE
APPROVED
A
RELEASED
02/23/2017
DS/NT
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 ARE IN INCHES TOLERANCES: FRACTIONAL
1/32
ANGULAR:
2
TWO PLACE DECIMAL
.03
THREE PLACE DECIMAL
.010
MATERIAL
FINISH
DRAWN
CHECKED
ENG APPR.
MFG APPR.
Q.A.
COMMENTS:
DATE
NAME
TITLE:
SIZE
B
DWG. NO.
REV
WEIGHT:
SCALE: 1:1
UNLESS OTHERWISE SPECIFIED:
A
SHEET 1 OF 1
89-03-0062-02
DO NOT SCALE DRAWING
INTERPRET GEOMETRIC TOLERANCING PER: ASME Y14.5M - 1994
ECR #:02161701
2/15/2017
WIRING INSTRUCTIONS,
4-20mA OPTION,
CD52 ATEX BANDIT
DS DS
02/15/2017
DM
02/20/2017 02/20/2017
JF JD
02/20/2017

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 16 of 48
SETUP & OPERATION
Detecon Methods
The CD52 Bandit detects pig passages via two very disnct methods:
permanent magnets and electromagnec transmiers. The advantages to
each method are discussed below.
Permanent Magnets
The Bandit will detect rare earth permanent magnets aached to a
pipeline pig. Magnets for this purpose are sold by CDI and are available for
pipelines from 50,8 mm to 1524 mm [2 in. to 60 in.] diameter.
38.10
1.500
PART #81-02-0007-00
PART #81-02-0006-00
1.260
32
292.10
11.500
THREAD
MAGNET FOR PIPES 32" THRU 48"
CD52 M3 MAGNET
1/2-13
NUT
of DWG-CD52-2003
1
FOR CD52 PIG DETECTION SYSTEM
CD52\Magnets\
TOP 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 = #
REVISEDM1,M2 & M3
AF. WHITE2/17/00
10/21/04
CHANGEDDIADIM 1.345 WAS 1.315 F. WHITE
ADDEDDECALWITH 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" THRU 30"
MAGNET FOR PIPES
THREAD
1/2-13
NOTES:
1. MAGNETS ARE HIGH STRENGTH
RARE EARTH PERMANENT MAGNETS.
2. MAGNETS M1 AND M2 ARE POTTED INTO PVC
OUTER SHELL, M3 IS POTTED INTO ALUMINUM.
3. DIMENSIONS ARE IN INCHES AND [MM].
NUT
34.93
1.375
CD52 M1 MAGNET
PART #81-02-0005-00
2.250
57.15
33.66
MAGNET FOR PIPES UP TO 12"
1.325
THREAD
1/2-13
NUT
NOTE: Where pipe wall thickness
exceeds 25.4 mm [1 in.], a custom
magnet design may be required.
Please consult CDI for an evaluaon
of deployment opons.

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 17 of 48
SETUP & OPERATION
Advantages of Permanent Magnets
• Small
• Inexpensive
• Low maintenance
• Baeries are not required
Despite these benets, because of the permanent magnet’s stac
magnec eld, it may be dicult to locate a pig that is stalled, obstructed,
or otherwise immobilized in a pipeline. In these situaons, an acve
(electromagnec) transmier is a recommended opon.
Electromagnec Transmiers
The CD52 Bandit detects acve electromagnec transmiers.
CDI oers the largest family of pipeline pig locaon and tracking
transmiers in the industry.
Our Transmiers operate by eming electromagnec elds at a very
low frequency (between 15 and 30 Hz). This makes CDI’s pig tracking
transmiers safe and reliable for use in any onshore or oshore
environment and any pipeline product (water, oil, gas, ammonia, carbon
dioxide, etc.).
Many models even have the ability to remain
dormant unl acvated by precongured
pipeline pressure.
CDI T-Series 22 Hz Electromagnec Transmiers

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 18 of 48
SETUP & OPERATION
Another advantage of CDI’s acve transmiers is the ease of locang
an immobilized pig. A stuck pig can easily be detected by walking
the pipeline from the last known locaon using a handheld acve locater
system. With that in mind, CDI is proud to oer our customers the
TRAXALL Mul-source Pig Locaon and Tracking System.
TRAXALL receivers are ideal for
tracking, locang, and pinpoinng
CDI X-Series electromagnec
transmiers, pigging industry-
standard 22 Hz “Legacy”
transmiers, and magnec-
ux leakage (MFL) pigs.
It is possible to use both a permanent magnet and a transmier in the
same pig. This will not prevent the Bandit, TRAXALL, or CD42 Receiver
systems from successfully tracking and locang pigs.
Regardless of which type of transmission source you use, the Bandit will
detect it.
Advantages of Electromagnec Transmiers
• Easily located with a handheld device
• Quicker to locate
CDI X-Series Adjustable-frequency Electromagnec Transmiers
(See your CDI distributor
or visit www.pigging.com
for more about TRAXALL!)

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 19 of 48
SETUP & OPERATION
The User Interface
The Bandit’s user interface display contains much informaon for an
operator, yet is quite simple and easy to read.
This display automacally cycles between showing the most recent pig
passage me, date and the actual real-me every seven (7) seconds.
This allows the operator to approach the Bandit on site and see the most
recent pig passage me and verify the internal clock is set correctly – all
without touching the unit.
Passage Time / Current Time
These display segments normally alternate between
showing the most recent pig passage and the actual
real-me as known by the unit. When the real-me is
displayed, the colon will blink (momentarily appear) and the “TIME” Acve
Funcon Indicator segment will display.
When the most recent pig passage me is displayed, the colon display
will be constant (non-blinking) and the “TIME” Acve Funcon Indicator
segment will not display.
Passage Date / Current Date
These segments normally alternate between displaying the
real-me date and the date of the most recent pig passage.
This date is in American format (MONTH–DATE; the year is
not displayed). Therefore, 4–05 would be April 5th, with the year assumed
to be current year.
ACTIVE
FUNCTION
INDICATORS
PASSAGE DATE
/CURRENT DATE
PASSAGE
INDICATOR
MARKED
RECENT
PASSAGE
INDICATOR
PASSAGE TIME
/CURRENT TIME
ACTIVE
FUNCTION
INDICATORS
PASSAGE DATE
/CURRENT DATE
PASSAGE
INDICATOR
MARKED
RECENT
PASSAGE
INDICATOR
PASSAGE TIME
/CURRENT TIME
ACTIVE
FUNCTION
INDICATORS
PASSAGE DATE
/CURRENT DATE
PASSAGE
INDICATOR
MARKED
RECENT
PASSAGE
INDICATOR
PASSAGE TIME
/CURRENT TIME

CD52 Bandit (ATEX-IECEx Cercaon) User Guide
Page 20 of 48
SETUP & OPERATION
Recent Passage Indicator
The Recent Passage Indicator segment at the
lower half of the Bandit’s display area indicates
that a pig passage has been recently detected.
The behavior of this segment conveys informaon about how recently the
pig passage occurred.
When a pig passage occurs, the segment will blink once per second for
one full hour aer the pig passage. Aer one hour, the display will
switch to a constant-on mode. This feature 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 mes recorded in
the Bandit’s memory. The larger the segment, the more recent the pig
passage.
MEANING
SEGMENT NOT LIT No passage detected
within the last 12 hours
SEGMENT BLINKING Passage was detected
within the last one hour
SEGMENT LIT,
NOT BLINKING
Passage was detected
more than one hour ago,
but less than 12 hours ago