Flowserve IPS Smart RTU User manual

USERINSTRUCTIONS
IPS Smart RTU
Installation
Operation
Maintenance
Multiple Sensor Input and Wireless Transmitting Unit
PCN = 26999987 6-14 (E). Original Instructions
These instructions must be read prior to installing,
operating, using and maintaining this equipment.
701-4101-01^

IPS SMART RTU ENGLISH 701-4101-01^ 6-14
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CONTENTS
1 INTRODUCTION AND SAFETY.......................... 3
1.1 GENERAL ......................................................... 3
1.2 CE MARKING AND APPROVALS .......................... 3
1.3 DISCLAIMER ..................................................... 3
1.4 COPYRIGHT...................................................... 3
1.5 DUTY CONDITIONS ............................................ 3
1.6 SAFETY............................................................ 4
1.7 SPECIFIC MACHINE PERFORMANCE .................... 4
1.8 SPECIFICATIONS............................................... 4
2 TRANSPORT AND STORAGE............................ 5
2.1 CONSIGNMENT RECEIPT AND UNPACKING............ 5
2.2 HANDLING......................................................... 6
2.3 STORAGE.......................................................... 6
2.4 RECYCLING AND END OF PRODUCT LIFE .............. 6
2.5 DISPOSAL INSTRUCTIONS................................... 6
3 DESCRIPTION..................................................... 6
3.1 OPTIONS AND MODEL NUMBERS......................... 7
3.2 DEFAULT CONFIGURATION ................................ 8
3.3 PERFORMANCE AND OPERATION LIMITS.............. 8
3.4 VB-103-TAM OPTIONAL ACCESSORY ............... 8
3.5 OVERALL VISUAL ALERT LIGHT (RTU-OVAL)
OPTIONAL ACCESSORY..................................... 8
3.6 INDIVIDUAL SENSOR ALERT LIGHT (RTU-SAL-
X) OPTIONAL ACCESSORY................................. 9
3.7 INDIVIDUAL BACKLIT SENSOR INFORMATION
DISPLAY (RTU-SID-X) OPTIONAL ACCESSORY.. 9
4 MAINTENANCE................................................... 9
4.1 TOOLS REQUIRED ............................................. 9
4.2 TURNING UNIT ON/OFF ...................................... 9
4.3 BATTERY REPLACEMENT................................... 9
5 CUSTOM CONFIGURATION PROGRAMMING10
6 INSTALLATION.................................................. 10
6.1 TOOLS REQUIRED ........................................... 11
6.2 UNPACKING.................................................... 11
6.3 PRELIMINARY OPERATIONAL CHECK ................. 11
6.4 INSTALLATION PREPARATION........................... 11
6.5 MOUNTING ..................................................... 12
6.6 CONNECTING SENSORS AND POWER-UP......... 12
6.7 CONNECTING TAKE AWAY MEMORY................. 13
6.8 VISUAL ALERT ACCESSORIES.......................... 13
7 PARTS LIST AND DRAWINGS......................... 13
7.1 SPARE PARTS ................................................ 13
7.2 DRAWINGS ..................................................... 14
8 CERTIFICATIONS............................................. 18
9 TROUBLE-SHOOTING GUIDE ......................... 18
9.1 LOSS OF COMMUNICATIONS ............................ 18
9.2 INACCURATE OR MISSING DATA....................... 19
9.3 NO DATA RECORDED ON VB-103-TAM........... 19
9.4 NO LIGHTS ON LIGHTS OR DISPLAY
ACCESSORIES ................................................ 19
10 DECLARATION OF CONFORMITY (TYPICAL)21

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1 INTRODUCTION AND SAFETY
1.1 General
These instructions must always be kept
close to the product's operating location or
directly with the product.
Flowserve products are designed, developed and
manufactured with state-of-the-art technologies in
modern facilities. The unit is produced with great
care and commitment to continuous quality control,
utilizing sophisticated quality techniques, and
safety requirements.
Flowserve is committed to continuous quality
improvement and being at your service for any
further information about the product in its
installation and operation or about its support
products, repair and diagnostic services.
These instructions are intended to facilitate
familiarization with the product and its permitted
use. Operating the product in compliance with
these instructions is important to help ensure
reliability in service and avoid risks. The
instructions may not take into account local
regulations; ensure such regulations are observed
by all, including those installing the product.
Always coordinate repair activity with operations
personnel, and follow all plant safety requirements
and applicable safety and health laws/regulations.
These instructions must be read prior to
installing, operating, using and maintaining the
equipment in any region worldwide. The
equipment must not be put into service until all
the conditions relating to safety, noted in the
instructions, have been met. Failure to follow
and apply the present user instructions is
considered to be misuse. Personal injury,
product damage, delay or failure caused by
misuse are not covered by the Flowserve
warranty.
1.2 CE Marking and approvals
It is a legal requirement that machineryand
equipment put into service within certain regions of
the world shallconform with the applicable CE
Marking Directives covering Machinery and, where
applicable, Low Voltage Equipment, Electromagnetic
Compatibility (EMC), Pressure Equipment Directive
(PED) and Equipment for Potentially Explosive
Atmospheres (ATEX).
Where applicable, the Directives and any additional
Approvals, cover important safety aspects relating to
machinery and equipment and the satisfactory
provision of technical documents and safety
instructions. Where applicable this document
incorporates information relevant to these Directives
and Approvals.
To confirm the Approvals applying and if the product
is CE marked, check the serial number plate
markings and the Certification. (See section
8CERTIFICATIONS.)
1.3 Disclaimer
Information in these User Instructions is believed
to be complete and reliable. However, in spite of
all of the efforts of Flowserve Corporation to
provide comprehensive instructions, good
engineering and safety practice should always be
used.
Flowserve manufactures products to exacting
International Quality Management System Standards
as certified and audited by external Quality Assurance
organizations. Genuine parts and accessories have
been designed, tested and incorporated into the
products to help ensure their continued product
quality and performance in use. As Flowserve cannot
test parts and accessories sourced from other
vendors the incorrect incorporation of such parts and
accessories may adversely affect the performance
and safety features of the products. The failure to
properlyselect, install or use authorized Flowserve
parts and accessories is considered to be misuse.
Damage or failure caused by misuse is not covered
by the Flowserve warranty. In addition, any
modification of Flowserve products or removal of
original components may impair the safety of these
products in their use.
1.4 Copyright
All rights reserved. No part of these instructions
may be reproduced, stored in a retrieval system or
transmitted in any form or by any means without
prior permission of Flowserve.
1.5 Duty conditions
This product has been selected to meet the
specifications of your purchase order. The
acknowledgement of these conditions has been
sent separately to the Purchaser. A copy should be
kept with these instructions.

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The product must not be operated beyond
the parameters specified for the application. If
there is any doubt as to the suitability of the
product for the application intended, contact
Flowserve for advice.
If the conditions of service on your purchase order are
going to be changed(for example: liquid pumped,
temperature or duty) it is requested that the user
seeks the written agreement of Flowserve before start
up.
1.6 Safety
1.6.1 Summary of safety markings
These User Instructions contain specific safety
markings where non-observance of an instruction
would cause hazards. The specific safety markings
are:
This symbol indicates electrical safety
instructions where non-compliance will involve a
high risk to personal safety or the loss of life.
This symbol indicates safety instructions
where non-compliance would affect personal safety
and could result in loss of life.
This symbol indicates “hazardous and toxic
fluid” safety instructions where non-compliance
would affect personal safety and could result in loss
of life.
This symbol indicates safety
instructions where non-compliance will involve some
risk to safe operation and personal safety and would
damage the equipment or property.
This symbol indicates explosive atmosphere
zone marking according to ATEX. It is used in
safety instructions where non-compliance in the
hazardous area would cause the risk of an
explosion.
This symbol is used in safety instructions to
remind not to rub non-metallic surfaces with a dry
cloth; ensure the cloth is damp. It is used in safety
instructions where non-compliance in the
hazardous area would cause the risk of an
explosion.
This sign is not asafety symbol but
indicates an important instruction in the assembly
process.
1.6.2 Personnel qualification and training
All personnel involved in the operation, installation,
inspection and maintenance of the unit must be
qualified to carry out the work involved. If the
personnel in question do not already possess the
necessary knowledge and skill, appropriate training
and instruction must be provided. If required the
operator may commission the
manufacturer/supplier to provide applicable
training.
Always coordinate repair activity with operations
and health and safety personnel, and follow all
plant safety requirements and applicable safety and
health laws and regulations.
1.6.3 Safety action
This is a summary of conditions and actions to
help prevent injury to personnel and damage to
the environment and to equipment. For
products used in potentially explosive
atmospheres section 1.6.4 also applies.
NEVER DO MAINTENANCE WORK
WHEN THE UNIT IS CONNECTED TO POWER
(Lock out.)
HANDLING COMPONENTS
Many precision parts have sharp corners and the
wearing of appropriate safety gloves and
equipment is required when handling these
components. To lift heavy pieces above 25 kg (55
lb.) use a crane appropriate for the mass and in
accordance with current local regulations.
1.6.4 Products used in potentially explosive
atmospheres
Measures are required to:
Avoid excess temperature
Prevent buildup of explosive mixtures
Prevent the generation of sparks
1.7Specific machine performance
For performance parameters see section 1.5 Duty
conditions. Where performance data has been
supplied separatelyto the purchaser these should be
obtained and retained with these User Instructions if
required.
1.8 Specifications
1.8.1 Smart RTU Unit Specifications
Operating frequency:
900 MHz or 868MHz
Channels:
2, 4, 6 or 8
Transmission rates:
5 seconds or higher
Operating range:
0.75 mile (1.21km)

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Operating
temperature:
-4°F to +104°F (-20°C to
+40°C)
Channel output
power:
16 to 24VDC
Channel output time:
Programmable
Humidity:
0-95% noncondensing
Inputs:
4-20mA, discrete, 0-
1VDC by channel
Power requirement:
12 or 24VDC, 110VAC
or 220VAC
Enclosure:
Fiberglass NEMA 4X
(size dependent on
accessories ordered)
Weight: (Solar Power)
15.50 lb (7.06kg)
(Battery or accessories
not included)
Weight: (AC Power)
15.00 lb (6.80kg)
(Battery or accessories
not included)
1.8.2 Optional add-on sensor specifications
RTD:
1000 or 100 Ohm
(Platinum, 2 wire)
Thermocouple:
Type: J, K, N, T, etc. (+
Cold Reference &
Polynomial)
Pressure:
Vacuum to 10Kpsi
(Specific sensor for
each range)
Vibration (Velocity):
Single Axis, Tri Axis
(0-1 ips)
(0-25 mm/sec)
Vibration:
(Acceleration):
0 - 10G Peak
Discrete:
Dry Contact Only
1.8.3 Optional RTU-OVAL specifications
Channels:
1 to 6
1.8.4Optional RTU-SAL-X specifications
Channels:
1 to 6
Humidity:
50% at 104°F (40°C)
Power requirement:
24VDC, 110VAC or
220VAC
Channel output
power:
24VDC
Expected Lamp Life:
100,000 Hours
Sensor Input Types:
Vibration (overall 4-
20mA signal),
Thermocouples, RTD
(PT100, PT1000),
Pressure, 4-20mA,
Discrete, Oil/Water,
Proximity Probes
1.8.5Optional RTU-SID-X specifications
Channels:
1 to 6
Operating Humidity:
0-90% noncondensing
Power requirement:
24VDC, 110VAC or
220VAC
Channel output
power:
24VDC
Sensor Input Types:
Vibration (overall 4-
20mA signal),
Thermocouples, RTD
(PT100, PT1000),
Pressure, 4-20mA,
Discrete, Oil/Water,
Proximity Probes
Display Digits:
Four digits, 0.25”
(6.4mm) high in pre-
specified engineering
units
Display Accuracy:
± 0.03% of span ± 1
count
Backlight:
Orange (intensity varies
with signal)
Error Display:
Display flashes “99999”
for over-range and “-
99999” for under-range
inputs
2 TRANSPORT AND STORAGE
Make sure that hazardous substances are
disposed of safely and that the correct personal
protective equipment is used. The safety
specifications must be in accordance with the
current local regulations at all times.
2.1 Consignment receipt and unpacking
Immediately after receipt of the equipment it must
be checked against the delivery/shipping
documents for its completeness and that there has
been no damage in transportation. Any shortage
and/or damage must be reported immediately to
Flowserve and must be received in writing within
ten days of receipt of the equipment. Later claims
cannot be accepted.
Check any crate, boxes or wrappings for any
accessories or spare parts that may be packed
separately with the equipment or attached to side
walls of the box or equipment.
Each product has a unique serial number. Check
that this number corresponds with that advised and
always quote this number in correspondence as
well as when ordering spare parts or further
accessories.

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2.2 Handling
Boxes, crates, pallets or cartons may be unloaded
using fork lift vehicles or slings dependent on their
size and construction.
2.3 Storage
Store the equipment in a clean, dry
location. The Smart RTU should be powered-down
prior to storage (see section 4 MAINTENANCE for
how to power down unit) to preserve battery life.
2.3.1 Storage and packaging
All Smart RTU units must be carefully packaged for
transport. Each unit should be boxed individually
with protective packaging (foam, bubble wrap, etc.)
in the box surrounding the unit.
After unpacking, protection will be the responsibility
of the user.
2.4 Recycling and end of product life
At the end of the service life of the product or its
parts, the relevant materials and parts should be
recycled or disposed of using an environmentally
acceptable method and in accordance with local
regulations. If the product contains substances that
are harmful to the environment, these should be
removed and disposed of in accordance with
current local regulations.
2.5 Disposal Instructions
At the end of the product’s life, do not
dispose of any electronic component or instrument
in the domestic waste. Disposal should be done in
accordance with applicable regulations, which vary
from state to state and country to country.
Battery Disposal Instructions: Disposal should
be done in accordance with applicable regulations,
which vary from country to country. Batteries
should not be incinerated, unless suitable
procedures are followed and qualified handlers
have taken appropriate precautions. Exposure of
these cells to high temperatures or fire can cause
the cells to vent and/or rupture. These cells do not
contain dangerous substances. The reaction
products are inorganic and do not represent
environmental hazards, once the decomposition or
neutralization process has terminated.
Disposal in Europe
Batteries for disposal should not be transported by
air. For road transport of dangerous goods ADR
special provision 636 and packing instruction 903a
apply.
Disposal in US
Hazardous waste of spent batteries can be disposed
after they are first neutralized through an approved
secondarytreatment prior to disposal. Disposal of
spent batteries should be performed byauthorized,
professional disposal company, which has the
knowledge in the requirements of the Federal, the
State and the Local authorities regarding hazardous
materials, transportation and waste disposal. In
any case it is recommended to contact the local
EPA office.
3 DESCRIPTION
The IPS Smart RTU model is a wireless
transmitting unit designed to monitor multiple
analog, discrete or IPS Wireless sensor inputs and
wirelessly transmit the data to a receiver. It has the
option of enabling wireless transmission (to
become part of an IPS Wireless system) or
disabling wireless functionality (to perform as a
local alert or data-logging unit).
Figure 1: Sample Smart RTU unit
The Smart RTU is either powered by a solar panel
or AC power and includes a built-in automatic
battery back-up system. It can monitor up to 8
different channels (dependent on accessories
ordered) of analog, digital or IPS Wireless sensor
inputs. The exact type of sensors monitored on
each channel is dependent on the individual unit
configuration. Consult factory for any applications
that require more than 8 channels per Smart RTU.

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At the pre-configured transmission time, the Smart
RTU reads the sensor data on a single channel,
transmits it and the moves on to the next channel
until all the channels have been read and data
transmitted.
Each unit also has a single diagnostics port (inside
the enclosure) for programming and
troubleshooting the unit as well as logging data with
the VB-103-TAM accessory (where collected data
is stored). Programming the unit requires a
programming cable and special software utility
(PSP).
The Smart RTU has a built-in omni-directional
wireless antenna, allowing for reliable signal
transmission. Data transmittal can occur at a
customizable time interval, ranging from every 5
seconds to once a day (this time interval is usually
pre-configured at the factory). Transmission rates
can also be varied according to sensor signal
values (see section 5 CUSTOM
CONFIGURATION PROGRAMMING), thereby
prolonging battery life. The Smart RTU has a
maximum data transmittal range of ¾ mile (1.2km)
under ideal conditions, but its effective transmission
range can be extended using a network of
repeaters.
Each Smart RTU can be part of a larger wireless
monitoring network. As such, each unit comes with
a calibration sheet from the factory which contains
unit-specific configuration information describing
the sensors and wireless network the unit is
configured for (parameters such as the wireless
system number, unit transmitter number, data
transmittal/check-in interval, scale factor and offset
to use with specific sensors). As long as your
specific application has been communicated to the
factory, the Smart RTU unit should come pre-
configured for your specific use.
3.1 Options and model numbers
The Smart RTU can either have wireless data
transmission enabled or disabled. In both settings,
certain accessories are only compatible with AC
powered Smart RTUs (see Table 1: Optional parts
for Smart RTU). Smart RTU units with wireless
transmission disabled are intended for use as local
data collectors with either the take away memory
(VB-103-TAM) or visual light alert modules.
The Smart RTU is available with the following
sensors as options to connect to inputs on the unit:
1. Vibration & Temperature (RTD) Combination
Sensor
2. Vibration Sensor
3. Temperature Sensor (RTD)
4. Temperature Sensor (Thermocouple)
5. Pressure Sensor
6. 4-20mA Analog Input Sensor
7. General Pulse Input Sensor
8. Tachometer (TTL)
9. Discrete Sensor
10. Vibration Sensor with FFT analysis output
11. Oil/Water Sensor
12. Proximity Probes
13. Serial Port RS-485 Interface
Additionally the Smart RTU has the following
options available:
Table 1: Optional parts for Smart RTU
Part Number
Description
301-4024
Programming cable: 5’
length, Serial Port- RS-485
connection
PSP
Unit Configuration Software
Utility
VB-103-TAM
Take-Away Memory Module
VB-101-DOCK
IPS Dock for communication
with VB-103-TAM Take-
Away Memory Module
TAM103 Utility
VB-103-TAM data download
and configuration software
RTU-OVAL (only
available on AC
powered Smart
RTU)
Overall Visual Alert Light
RTU-SAL-X (only
available on AC
powered Smart
RTU, X
designates the
number of sensors
to have alert
lights)
Sensor Alert Light (per input)
RTU-SID-X (only
available on AC
powered Smart
RTU, X
designates the
number of sensors
to have alert
lights)
Backlit Sensor Information
Display (per input)
The exact configuration of different sensors
attached to each Smart RTU unit is limited to
certain combinations. Contact the factory for a

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complete list of the different configurations
available for the Smart RTU.
3.2 Default Configuration
The Smart RTU is configured to the following
parameters by default, unless otherwise specified.
Table 2: Parameter default configuration values
for Smart RTU
Parameter
Name
Parameter
Description
Default
Value
Normal
Measurement
Interval
How often data is
read from each of
the sensors by the
Smart RTU
5 minutes
3.3Performance and operation limits
This product has been selected to meet the
specification of your purchase order.
The following data is included as additional
information to help with your installation. This is
typical information and if required, a definitive
statement for your applicationcan be obtained from
Flowserve.
Smart RTU material compatibility is
the responsibility of the end user.
3.3.1 Sensor specifications
Refer to section 1.8 Specifications for available
sensor specifications.
3.3.2 Battery
Power is provided by a user-
replaceable sealed lead acid 12V battery, located
inside the Smart RTU enclosure.
Battery life is dependent upon data transmittal
intervals and charging system operation. Battery
voltage should normally be between 12.0 and
12.8VDC. If it is lower than 11V, the battery will
need to be replaced with the one specified on the
wiring diagram. The battery voltage can be read
using a voltmeter (with the charging system fuse
opened). The battery is then charged by either a
solar panel or an AC power supply (dependent on
specific unit). Typically the battery is expected to
last 5 years, if the charging system is properly
functional.
3.4 VB-103-TAM Optional Accessory
The VB-103-TAM is an optional Take Away
Memory module for the Smart RTU. When
connected to a Smart RTU, it automatically logs
data from all sensors at the preconfigured log
interval. Data from the VB-103-TAM and the log
interval can be reviewed utilizing an IPS Dock
connected to a PC. The VB-103-TAM is set to a
default log interval (how often current data from the
Smart RTU is logged to the VB-103-TAM device) of
5 minutes (300 seconds), unless otherwise
specified. This is independent of the normal
measurement interval of the Smart RTU which
governs how often sensors are read.
The battery logged on the VB-103-TAM
unit represents an internal voltage being supplied
to the RTU board. This battery voltage reading
should normally be around 3.3V and is not directly
representative of the RTU battery-backup voltage
or AC/solar power supply voltage.
The VB-103-TAM has a separate battery
that governs the lifetime of this unit. The expected
life of this battery is 6 years at the default 5 minute
log interval. The battery in the VB-103-TAM is not
replaceable and requires replacing the VB-103-
TAM unit when it is depleted.
The VB-103-TAM also has a finite amount of data
storage available. Dependent on the amount of
data points being measured and the measurement
interval, this storage capacity is defined as listed in
the table below.
Table 3: VB-103-TAM data storage capacity at
various measurement intervals and numbers of
data parameters
Measurement Interval
Data
Points
5 s
10 s
30 s
1
min
2
min
5
min
10
min
1
50
day
100
day
10
mo
1.6
yrs
3.3
yrs
4 yrs
4 yrs
2
25
day
50
day
5
mo
10
mo
1.6
yrs
4 yrs
4 yrs
3
16
day
33
day
3.3
mo
6.6
mo
1.1
yrs
2.7
yrs
4 yrs
4
12
day
25
day
2.5
mo
5
mo
10
mo
2 yrs
4 yrs
5
10
day
20
day
2
mo
4
mo
8
mo
1.6
yrs
3.3
yrs
6
8
day
16
day
50
day
100
day
6.6
mo
16.6
mo
2.7
yrs
7
7
day
14
day
42
day
2.8
mo
5.7
mo
14.2
mo
28.5
mo
3.5Overall Visual Alert Light (RTU-
OVAL) Optional Accessory
The Overall Visual Alert Light (RTU-OVAL) is an
optional accessory for the Smart RTU. When
connected to a Smart RTU, it automatically

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provides a visual light indication if any sensors on
the Smart RTU unit are or have been in alarm
status. To define the alarm limits for each sensor,
refer to Section 5 CUSTOM CONFIGURATION
PROGRAMMING.
The table below describes each of the different
types of indications offered by the RTU-OVAL
accessory.
Table 4: RTU-OVAL visual alert description
LED
State
Description
GREEN
Light
flashes on
for 400
milliseconds
Normal operation –all sensors are
within acceptable limits
RED
Light
flashes on
for 400
milliseconds
Current alarm –one of the sensor
measurements has exceeded its alarm
limit and has not returned within the
acceptable range
RED &
GREEN
Each color
light flashes
on for 400
milliseconds
Alarm –one of the sensor measurements
previously exceeded its alarm limit, but has
now returned within the acceptable range
The time period for which the RTU-OVAL lights will
flash to indicate a past alarm event is set to 14
days by default.
3.6Individual Sensor Alert Light (RTU-
SAL-X) Optional Accessory
The Individual Sensor Alert Lights (RTU-SAL-X)
are an optional accessory for the Smart RTU.
When installed in a Smart RTU, each light
automatically provides a visual light indication if its
particular sensor is in alarm status. Each sensor
on the Smart RTU requires its own Sensor Alert
Light. To define the alarm limits for each sensor,
refer to Section 5 CUSTOM CONFIGURATION
PROGRAMMING.
3.7Individual Backlit Sensor
Information Display (RTU-SID-X)
Optional Accessory
The Individual Backlist Sensor Information Displays
(RTU-SID-X) are an optional accessory for the
Smart RTU. When installed in a Smart RTU, each
display shows the actual current applicable sensor
reading in the predefined engineering units.
Each sensor on the Smart RTU requires its own
Sensor Information Display. Refer to the Smart
RTU test sheet to determine the engineering units
configured for each sensor.
4MAINTENANCE
The only field maintenance required on the Smart
RTU is checking the battery and charging system.
The Smart RTU can also be turned off when not in
use for extended periods of time to conserve
battery life.
4.1 Tools required
Set of SAE wrenches
Phillips head screwdriver
Small flat-head screwdriver
Voltmeter
4.2Turning unit on/off
To power off Smart RTU disconnect the fuse for the
battery cables and the wires coming from the
power supply or solar panel (refer to included
wiring diagram to identify the correct fuse blocks).
This will stop sensor readings and data
transmission.
To power up the Smart RTU again, simply
reconnect the battery and power supply or solar
panel fuses inside the enclosure (refer to included
wiring diagram to identify the correct fuse blocks).
This will activate sensor readings and data
transmission at the pre-configured intervals.
Figure 2: Fuses on inside of Smart RTU
enclosure
4.3 Battery Replacement
EXPLOSION HAZARD: Do not open
enclosure when an explosive atmosphere may be
present. The unit must be powered OFF during the
battery installation.
WARNING STATIC HAZARD: Wipe only with
a damp cloth due to electrostatic discharge hazard.
The substitution of components may
impair intrinsic safety.

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Power is provided by a sealed lead acid 12V
battery located inside the Smart RTU enclosure.
The battery is then charged by either a solar panel
or an AC power supply (dependent on specific
unit). Battery voltage should normally be between
12.0 and 12.8 VDC. If the battery level is lower
than 11V, the battery will need to be replaced. The
battery voltage can be read by using a voltmeter
(with the charging system fuse opened).
The battery pack shall only be replaced with
PowerSonic model numbers PS-12180 (for a solar
powered Smart RTU) or PS-1270 (for AC powered
Smart RTU). Replacement batteries can also be
obtained by contacting your local Flowserve
representative (battery pack part numbers G1-0005
& G1-0004).
Perform the following steps to replace the battery:
1. Ensure an explosive atmosphere is not
present, and then open the cover of the Smart
RTU enclosure.
2. Power down unit by removing the battery and
power supply/solar panel fuses inside the
enclosure.
3. Disconnect the wires connecting to the battery
terminals.
Figure 3: Wires going to battery terminals
inside Smart RTU enclosure
4. Remove old battery and place new battery
inside enclosure.
5. Connect battery cables to terminals of new
battery.
6. Reconnect battery and power supply/solar
panel fuses.
7. Ensure Smart RTU powers up, then close
enclosure cover.
8. Dispose of old battery in accordance with local
laws and regulations.
5 CUSTOM CONFIGURATION
PROGRAMMING
This section is optional. As long as your
specific application was communicated to the
factory prior to shipment, the Smart RTU unit is
pre-configured for your specific use.
Errors in programming
configuration can render the Smart RTU
inoperable, proceed with caution. Flowserve is
not liable for any damage caused by user
configuration errors.
For instructions on how to change software
configuration options on the Smart RTU, refer to
the PSP software user instructions. The list below
provides an overview of the functions that can be
performed using this software utility:
- Reading & saving Smart RTU configuration
- View & modify Smart RTU transmission
intervals
- Setting the time on the Smart RTU
- Calibration of individual sensors on Smart
RTU
- Read live data from sensors on the Smart
RTU
- Change alarm levels on the Smart RTU
(also affecting the RTU-OVAL accessory)
- Turn specific Smart RTU sensor channels
on or off
For instructions on how to perform software options
on the VB-103-TAM unit, refer to the IPS Dock user
instructions. The list below provides an overview of
the functions that can be performed using the IPS
Dock and appropriate software utility:
- Reading & saving VB-103-TAM log data
- Clearing the log from the VB-103-TAM
- Setting the time on the VB-103-TAM
- Changing the data logging interval on the
VB-103-TAM
For instructions on how to change the alarm levels
for the RTU-SAL-X optional accessory, refer to the
signal conditioning module user instructions. Note:
this will require a special programming cable and
software utility.
6INSTALLATION
Always wear appropriate personal
protective equipment during the installation of
Smart RTU units.

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6.1 Tools required
Tools required to install the various
mounting configurations are conditional
based on the type of mounting and location
Set of SAE wrenches
Phillips head screwdriver
Small flat-head screwdriver
Voltmeter
6.2 Unpacking
Carefully open package received from
factory and remove protective wrapping from Smart
RTU units and accessories. Inspect all hardware
for damage. Report any damage to shipping
carrier immediately.
Ensure you have received the correct sensors and
mounting accessories for your application. Cross-
check hardware received versus packing slip and
purchase order.
Record unit serial numbers for future reference.
6.2.1 Electrostatic Discharge (ESD) Handling
Procedure
The Smart RTU contains sensitive electronic
components that may be damaged by static
electricity present in work environments. The
following precautions are recommended to reduce
the risk of damage due to electrostatic discharge:
Only wipe exterior of unit with a damp cloth
Use of a grounding wrist strap when removing
inner enclosure cover is recommended
6.3 Preliminary operational check
After unpacking and before field installation,
perform the following operational check on the unit:
1. Ensure the fuse for the battery is disconnected.
This keeps the unit powered down during the
installation process.
2. Place Smart RTU in vertical position with a
clear line of sight to and close to (< 3.048 m
(<10 ft.)) the receiver. If only using the VB-
103-TAM or local display accessories, simply
place Smart RTU in a vertical position.
3. Insert sensor wire(s) into the proper terminals.
4. Ensure battery is connected to battery terminal
wires, and then connect the battery fuse to
power up the unit. Install the VB-103-TAM to
the Smart RTU (if applicable).
5. Ensure the receiver is receiving data from the
unit. If applicable, let the VB-103-TAM log data
for a few minutes and confirm appropriate light
operation of the light and data display units as
applicable.
6. If applicable, disconnect VB-103-TAM and use
IPS Dock to confirm accurate data has been
logged (refer to IPS Dock user instructions for
how to do this).
7. Disconnect fuse for the battery to power down
the unit. Disconnect and remove battery.
8. Disconnect sensor wire(s) from terminals.
In case of issues with powering up the unit, refer to
section 9 Trouble-Shooting Guide.
6.4 Installation Preparation
Prior to mounting the Smart RTU in the field, two
penetrations will need to be drilled in the enclosure
to accommodate connections for power and sensor
wiring. It is recommended that the penetrations be
drilled in the bottom of the enclosure to minimize
moisture and/or dust entry to the enclosure. Two
penetrations are needed to be able to route the
power and sensor wiring through separate
conduits.
The size of each penetration is user-dependent,
they should be large enough to accommodate all
the cables to be run through each penetration.
Penetrations should be made in accordance with
the local electrical wiring code (such as NEC/CEC).
While penetrating the enclosure and installing the
fittings, take care not to damage the internal wiring
and boards of the Smart RTU.
Figure 4: Inside of Smart RTU enclosure with
penetrations made

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Figure 5: Outside of bottom portion of Smart
RTU enclosure with conduit going into
penetrations in enclosure
6.5 Mounting
Each unit should be clear of physical obstructions
to the receiver and/or repeater(s) in order to
maintain consistent communications (if applicable).
If the Smart RTU is solar powered, a location with
at least 6 hours of unobstructed daily sunlight and
an equatorial exposure should be considered.
The Smart RTU is designed to be mounted in a
vertical position and should only be mounted in a
horizontal position with approval from the factory.
Ensure the Smart RTU is not subjected to
excessive vibration unless a routine maintenance
program includes verification of associated
connections. The Smart RTU unit should be
installed near but not on process equipment being
monitored.
Mount the Smart RTU unit before connecting any of
the sensor cables.
The Smart RTU is designed to be bolted to 2
pieces of horizontal unistrut. First, both these
pieces of unistrut should be mounted horizontally to
a support structure (poles, pipe, hand-rail, wall, etc)
using the necessary hardware (U-bolts, studs,
bolts, etc). Then, use the mounting holes on the
back of the Smart RTU enclosure to bolt the unit to
the pieces of unistrut.
Next, if applicable, install the solar panel facing the
equator with a tilt (from horizontal) of about 15
degrees plus your location’s latitude.
Figure 6: Sample installed solar powered Smart
RTU
6.6 Connecting Sensors and Power-Up
Install all sensors on equipment to be monitored.
Wiring for the solar panel or AC power should be
run into the Smart RTU through an enclosure
penetration. Terminate these wires according to
the local electrical wiring code (such as NEC/CEC),
but do not connect them to the terminal blocks yet.
Run sensor wiring through a separate conduit into
a separate penetration into the Smart RTU.
Terminate these wires and connect them to the
appropriate terminal blocks according to the wiring
diagram supplied with your particular Smart RTU
unit.
4-20mA current signals can be wired 3 different
ways depending on the type of sensor.
For a loop powered 4-20mA device, connect wires
as follows:
-Connect the positive (power supply) of
sensor wire to the 24VDC+ terminal
block
-Connect negative (signal) of sensor
wire to channel Signal+ terminal block
For a 3-wire 4-20mA device, connect wires as
follows:
-Connect positive signal wire to channel
Signal+ terminal block
-Connect negative wire to channel COM
(or Signal-) terminal block
-Connect power wire to 24VDC+
terminal block

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For a 4-wire 4-20mA device, connect wires as
follows:
-Connect positive of sensor wire to
channel Signal+ terminal block
-Connect negative of sensor wire to
channel COM (or Signal-) terminal
block
-Connect sensor external power
positive wire to the 24VDC+ terminal
block
-Connect sensor external power
negative wire to COM terminal block
Ensure all sensor wires are
connected to the terminal blocks first.
Then, connect the AC or solar panel wires to the
appropriate terminal blocks. Next, install the
battery inside the enclosure and connect the
Battery+ and Battery- wires to the terminals. Close
all fuses to power up the unit.
Figure 7: Sample Smart RTU unit with sensor
wires connected to terminal blocks
6.7Connecting Take Away Memory
Open the Smart RTU enclosure and install the VB-
103-TAM into the amphenol-style connection on
the backpanel. The VB-103-TAM will automatically
start logging data from the Smart RTU unit at its
preconfigured log interval. Close the Smart RTU
enclosure.
To change the logging interval or download data
from the VB-103-TAM, refer to the IPS Dock User
Instructions.
6.8Visual Alert Accessories
The Overall Visual Alert Light (RTU-OVAL),
Individual Sensor Alert Light(s) (RTU-SAL-X) and
Individual Sensor Information Display(s) (RTU-SID-
X) are already installed on the Smart RTU unit if
ordered. They do not require any further
installation or configuration. These accessories
should only be installed or uninstalled by the
factory.
The RTU-OVAL Module will automatically reflect
the alarm status of all sensors on the Smart RTU.
The RTU-SAL-X light(s) will turn on to provide a
visual light indication if the applicable sensor is in
alarm status. To define the alarm limits for each
sensor, refer to Section 5 CUSTOM
CONFIGURATION PROGRAMMING.
The RTU-SID-X display(s) will show the actual
current applicable sensor reading in the predefined
engineering units.
7PARTS LIST AND DRAWINGS
7.1 Spare Parts
Available spare parts for the Smart RTU unit are
shown below. No spare parts are needed during
start-up. Recommended quantities of 2-year
operational spares are listed below.
Table 5: Smart RTU Spare Parts
Part
Number
Description
Recommend
Quantity for
2-Year Operational
Spares
G1-0005
(for solar
powered
RTU)
Replacement Battery,
12V, 18Ah
1
G1-0004
(for AC
powered
RTU)
Replacement Battery,
12V, 7Ah
1
G2-0003
(for solar
powered
RTU)
Replacement Solar
Panel, 12V, 20W
1
H0-0122
Replacement fuse, 0.5A
2
H0-0129
Replacement fuse, 2.5A
2
H0-0131
Replacement fuse, 0.0
32A
6
M1-0085
SS cap for VB-103-TAM
connection ports (single)
1

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7.2 Drawings
Figure 8: AC Powered Smart RTU drawing

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Figure 9: Solar Powered Smart RTU

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Figure 10: Smart RTU with RTU-OVAL, RTU-SAL and RTU-SID accessories

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Figure 11: Inside of Smart RTU with RTU-OVAL, RTU-SAL and RTU-SID accessories

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8CERTIFICATIONS
The following certifications are applicable to the Smart
RTU:
Table 6: Smart RTU (Model S-EGI-NB-4/20RTU)
certifications
0518
II 3 GD
Ex nA IIC T6
Cl I, Div 2, Grp A,B,C,D; Cl II,
Div2, Grp E,F,G, T6
Cl I, Zone 2, A/Ex nA IIC T6
Type 4X
-20°C ≤ Ta ≤ +40°C
Electrical Ratings: 115/230 Vac, 1.3/0.7A, 50-60 Hz
CAUTIONS: OPEN CIRCUIT BEFORE REMOVING COVER.
KEEP COVER TIGHT WHILE CIRCUITS ARE LIVE.
WARNING: SUBSTITUTION OF COMPONENTS MAY
IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.
DO NOT DISCONNECT BATTERY OR EQUIPMENT
UNLESS THE AREA IS KNOWN TO BE NON-HAZARDOUS.
USE ONLY POWER SONIC BATTERY PART NUMBER PS-
1270 OR PS-12180.
9TROUBLE-SHOOTING GUIDE
EXPLOSION HAZARD: The unit must be
powered OFF during the battery installation & must
be in a General Purpose Classified Area before
opening outside enclosure to prevent the possible
ignition of a hazardous atmosphere.
9.1 Loss of Communications
Loss of communications with Smart RTU unit may
occur for several reasons:
Unit not powered up
Unit not configured correctly
Unit out of range of receiver
Receiver not configured correctly
See solutions below to each of the possible
causes:
9.1.1 Unit Not Powered Up
Verify battery and power supply/solar panel fuses
are connected and not blown (refer to included
wiring diagram for where these fuses are located).
1. Open the power supply/solar panel fuse.
2. Read battery level using voltmeter connected
to battery terminals. If the battery level is
below 11V, replace the battery according to
instructions in section 4 MAINTENANCE.
3. If communications are still not successful,
confirm the power source being used to charge
the battery. This procedure will vary depending
on if your unit has a solar panel or AC power
input.
a. AC Power: confirm the voltage
coming out of the 24V power
supply is close to 24VDC. If there
is no output from the power supply,
confirm that AC power is
connected to the power supply. If
the AC power connection is
working, the power supply will
need to be replaced. Contact the
Flowserve factory for assistance.
b. Solar Panel: confirm the power
coming out of the power regulator
is 12VDC or higher. If there is no
output from the regulator, confirm
that the solar panel is connected to
the input and functional. If the
solar panel supply is working, the
voltage regulator will need to be
replaced. Contact the Flowserve
factory for assistance.
Figure 12: Measuring AC power supply output
on Smart RTU using a voltmeter
9.1.2 Unit Not configured Correctly
To perform the diagnostic steps for this issue, the
Smart RTU unit will need all sensors connected to
it.
Refer to PSP software instructions to reload the
original configuration into the Smart RTU unit.
9.1.3 Unit Out of Range of Receiver
If communications from the Smart RTU unit to the
receiver are still not successful, physically move
the Smart RTU unit next to and with a clear line of
sight to the receiver.

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If data is being read from this location, then ensure
that the repeater network is appropriately located
and functional.
9.1.4 Receiver Not Configured Correctly
Check receiver configuration to ensure it is set up
to receive data from this particular Smart RTU unit
(refer to receiver user instructions).
If none of the above solutions are successful in
getting data reception at the receiver, contact the
factory for additional support.
9.2 Inaccurate or Missing Data
If the data being read from the Smart RTU unit is
either inaccurate or missing, this could have
several causes:
Incorrect/loose cable connections
Unit configuration incorrect
Inaccurate sensor calibration
Incorrect receiver configuration
Sensors not installed correctly on equipment
9.2.1 Incorrect/Loose Cable Connections
Ensure the sensor cables to the Smart RTU are in
accordance with the wiring diagram supplied with
the unit. Reconnect all sensor wires to ensure tight
connections on wiring (ensure terminal blocks are
not clamped down on insulation of wires).
9.2.2 Unit Configuration Incorrect
If the inaccurate/missing data problem is across all
sensors, reload the original configuration for the
Smart RTU unit (see PSP user instructions).
9.2.3 Inaccurate Sensor Calibration
If the data received on certain channels/sensors is
not accurate, recalibrate those sensors (see PSP
user instructions).
9.2.4 Incorrect Receiver Configuration
Refer to receiver instructions to confirm correct
configuration. If necessary, contact factory to
reload receiver configuration settings.
9.2.5 Sensors Not Installed Correctly on
Equipment
Check physical installation of sensors on
equipment being monitored.
9.3 No Data Recorded on VB-103-TAM
If no data is being stored to the VB-103-TAM unit,
this could have several causes:
Incorrect/loose sensor cable connections
Loose VB-103-TAM connection
Low battery on VB-103-TAM
Incorrect VB-103-TAM log interval
configuration
9.3.1 Incorrect/Loose Sensor Cable
Connections
Ensure the sensor cables to the Smart RTU are in
accordance with the wiring diagram supplied with
the unit. Reconnect all sensor wires to ensure tight
connections on wiring (ensure terminal blocks are
not clamped down on insulation of wires).
9.3.2 Loose VB-103-TAM Connection
Ensure the VB-103-TAM and Smart RTU 6-pin
amphenol style ports are free from dust and debris.
Use compressed moisture free air to blow out any
debris if needed.
Disconnect and reconnect the VB-103-TAM from
the Smart RTU unit. Ensure that VB-103-TAM is
completely and fully threaded onto the Smart RTU
6-pin amphenol style connector (tighten VB-103-
TAM onto amphenol style connector, push VB-103-
TAM gently onto connector and then tighten further
until it will go no further to ensure proper
connection).
9.3.3 Low Battery on VB-103-TAM
Check to see if VB-103-TAM unit can be read on
an IPS Dock. If not, replace VB-103-TAM unit (the
VB-103-TAM battery is not user replaceable).
9.3.4 Incorrect VB-103-TAM Log Interval
Configuration
Connect the VB-103-TAM to the IPS Dock and
ensure the log interval is set to the expected value
(see IPS Dock user instructions for additional
details on how to perform this task).
9.4 No Lights on Lights or Display
Accessories
If no lights are flashing on the RTU-OVAL or RTU-
SAL-X lights accessories or no data is shown on
the RTU-SID-X display, this could have several
causes:
Unit not powered up
Loose wiring connections
9.4.1 Unit Not Powered Up
Verify battery and power supply/solar panel fuses
are connected and not blown (refer to included
wiring diagram for where these fuses are located).
1. Open the power supply/solar panel fuse.
2. Read battery level using voltmeter connected
to battery terminals. If the battery level is

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below 11V, replace the battery according to
instructions in section 4 MAINTENANCE.
3. If communications are still not successful,
confirm the power source being used to charge
the battery. This procedure will vary depending
on if your unit has a solar panel or AC power
input.
a. AC Power: confirm the voltage
coming out of the 24V power
supply is close to 24VDC. If there
is no output from the power supply,
confirm that AC power is
connected to the power supply. If
the AC power connection is
working, the power supply will
need to be replaced. Contact the
Flowserve factory for assistance.
b. Solar Panel: confirm the power
coming out of the power regulator
is 12VDC or higher. If there is no
output from the regulator, confirm
that the solar panel is connected to
the input and functional. If the
solar panel supply is working, the
voltage regulator will need to be
replaced. Contact the Flowserve
factory for assistance.
Figure 13: Measuring AC power supply output
on Smart RTU using a voltmeter
9.4.2 Loose Wiring Connections
Ensure the RTU-OVAL, RTU-SAL-X lights and
RTU-SID-X display accessories are in accordance
with the wiring diagram supplied with the unit.
If none of the above solutions are successful in
resolving the issue, contact the factory for
additional support.