Online Electronics 4003 MAGSIG User manual

Online Electronics Limited
+ 44 (0) 1224 714714
[e-mail]
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

4003_5001_D02 Page 1 of 35
4003_5001
Rev
Date
By
Summary of change
A00
16/05/18
GH
Initial Release
B00
14/09/18
AW
Updates + MODBUS detail
B01
29/10/18
AW
Special conditions and markings updated.
B02
31/10/18
BG
Sections 4.8 & 4.10 updated.
B03
12/12/18
BG
Weights updated
B04
27/06/19
AW
Updates due to firmware changes, affecting menu, and PCB affecting
labelling of Interface PCB and power supply/CL.
Warnings added with reference to intrinsic safe equipment. Section 5
BLUETOOTH INTEGRATION 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 changes after review
C05
13/05/20
TL
CR00914: Minor changes to sections 2.2 & 4.10.2.
D00
15/05/20
AW
CR00857: Minor updates + LoRa [Firmware RevD].
D01
15/07/20
BG
CR00939; Section 2.2 updated
D02
13/10/20
BG
CR00958; Section 2.1 Note for Battery Life added, minor updates
throughout.
COMMENTS:

4003_5001_D02 Page 2 of 35
CONTENTS Page
1. GENERAL DESCRIPTION ......................................................................................... 4
2. SPECIFICATIONS ................................................................................................... 5
2.1. GENERAL .......................................................................................................... 5
2.2. STANDARD OUTPUTS ......................................................................................... 5
2.3. OPTION OUTPUTS.............................................................................................. 5
2.3.1. LoRa Radio Modem ........................................................................................ 5
3. RULES FOR SAFE OPERATION ................................................................................. 6
4. OPERATION .......................................................................................................... 7
4.1. TURNING ON..................................................................................................... 7
4.2. STABILISATION................................................................................................. 8
4.3. LISTENING ....................................................................................................... 8
4.4. DETECTION MODE ............................................................................................. 9
4.4.1. PIG PASSED .................................................................................................. 9
4.4.2. PIG DETECTION ONLY .................................................................................... 9
4.4.3. DETECTION DELAY....................................................................................... 10
4.5. SINGLE BUTTON MENU INTERFACE.................................................................... 11
4.5.1. VIEW EVENTS ............................................................................................. 13
4.5.2. COPY EVENTS TO SD CARD........................................................................... 13
4.5.3. DELETE ALL EVENTS .................................................................................... 13
4.5.4. SHUTDOWN ................................................................................................ 13
4.5.5. DATE.......................................................................................................... 14
4.5.6. TIME .......................................................................................................... 14
4.5.7. THRESHOLD................................................................................................ 14
4.5.8. POWER MODE ............................................................................................. 14
4.5.9. STABILISATION DELAY ................................................................................. 14
4.5.10. 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 INTERFACE ....................................................................... 17
4.6.1. MODBUS REGISTER MAP .............................................................................. 17
4.7. EVENT LOGGING AND SD CARD ........................................................................ 20
4.7.1. EVENT LOGGING ......................................................................................... 20
4.7.2. SD CARD .................................................................................................... 20
4.8. MOUNTING ..................................................................................................... 21
4.8.1. REMOTE SENSOR MOUNTING ........................................................................ 21
4.9. BATTERY REPLACEMENT ................................................................................... 22
4.10. EXTERNAL CONNECTIONS ................................................................................ 23
4.10.1. RELAY OUTPUT ............................................................................................ 24
4.10.2. CURRENT LOOP OUTPUT ............................................................................... 24
4.11. INTERNAL HEATER........................................................................................... 24
4.12. RTC BACKUP ................................................................................................... 25
4.13. LoRa .............................................................................................................. 26
4.14. RECOMMENDED MAGNET ARRANGEMENT ........................................................... 28
5. BLUETOOTH INTEGRATION ................................................................................... 29

4003_5001_D02 Page 3 of 35
5.1. BLUETOOTH 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

4003_5001_D02 Page 4 of 35
1. GENERAL DESCRIPTION
The OnlinE 4003 MAGSIG® is a robust, non-intrusive magnetic pig signaller which detects,
signals, and logs the passage of magnetic pigs at critical points along a pipeline both on land
and offshore. Events are signalled as they occur via an OLED dot matrix display and high
brightness LEDs positioned around the perimeter of the display.
The unit logs the time and date of up to 100 events. Logged events can be viewed locally on the
dot matrix display, transmitted remotely over several optional interfaces, or downloaded using
a laptop or onto a SD card. The unit can also continuously log sensor data to SD card. The user
can turn the unit ON and OFF as well as modify several settings using the single control button
and intuitive menu system.
The unit can be quickly and easily attached to a pipeline using ratchet straps or steel banding.
The unit is suitable for use on pipeline diameters up to 60” with wall thickness up to, and in
excess, of 40mm (please contact Online Electronics Ltd when wall thickness exceeds 25mm).
Detection speed ranges from 0.01 to 20 metres per second. Window of detection is typically
0.5m either side of the unit. The detection capabilities vary depending on the background
magnetic noise, pig speed, pipeline diameter, wall thickness 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 cells which can either all be Alkaline (DURACELL ID1300)
OR NiMH (Annsman Max E –ATEX/IECEx only). The 4003 also caters for 2 off Lithium (SAFT
LS33600) cells, this option being configured at manufacture.
ENTRY OPTIONS: The standard unit comes with 2 off ¾” NPT entries with blanking elements
installed. There is room inside the unit to make electrical connections without the need for
additional junction boxes or enclosures. Certified adaptors are generally available for other
thread types.
REMOTE SENSOR OPTION: The 4003 sensor is available in its own metal housing and is
connected to the main unit via solid or flexible conduit. A junction box provides 2 entries for
external electrical and signal connections.
MATERIAL OPTIONS: The unit can be supplied with an epoxy coated Aluminium Alloy 6082-
T6 or uncoated 316L Stainless Steel housing. Alternative coatings can be catered for.
TEMPERATURE RANGE OPTIONS: Ambient temperatures of -50°C can be accommodated by
installing a heater within the electronics housing. Higher pipeline surface temperatures can be
accommodated using a thermally insulated remote sensor.

4003_5001_D02 Page 5 of 35
2. SPECIFICATIONS
2.1. GENERAL
External supply ....................................................................+21.6Vdc to +26.4Vdc, <1.0W
Loop powered current loop ................................................................................... 8- 20mA
Temperature range using external supply (NO CELLS FITTED) -50°C to +85°C (-58 to +185°F)
Battery type ..................................................................4x DURACELL ID1300 Alkaline cells
Battery type ........................................................................ 2x SAFT LS33600 Lithium cells
Battery life in Listening/Low Power Mode at +20°C ..................................up to 400 Days Note 1
Temperature range while cells installed ...................Refer to Section 9 SAFETY INSTRUCTIONS
Ingress Protection ..................................................................................... IP66 / NEMA 4X
ATEX/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 Contacts) ............................................................ 2A @ 30Vdc
ISA TYPE II 2 wire Current Loop Output ...............................................>18mA (DETECTION)
MODBUS ......................................................................................................RTU (RS485)
BLUETOOTH................................................................................................. Class 4 (BLE)
2.3. OPTION OUTPUTS
2.3.1. LORA RADIO MODEM
LoRa .............................................................. Radio frequency configured for country of use
External supply ....................................................................+21.6Vdc to +26.4Vdc, <5.0W
Battery type ........................................................................ 2x SAFT LS33600 Lithium cells

4003_5001_D02 Page 6 of 35
3. RULES FOR SAFE OPERATION
󱛻󱛼󱛽WARNING: The Special Conditions for Safe Use detailed in Section 9 SAFETY INSTRUCTIONS
of this manual must be observed at all times.
󱛻󱛼󱛽WARNING: The purchaser of this equipment is responsible for the 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 the
batteries are removed and stored separately.

4003_5001_D02 Page 7 of 35
4. OPERATION
Familiarise yourself with the rules for safe operation of this equipment as described in Section 3
RULES FOR SAFE OPERATION.
The 4003 provides a 2x16 OLED dot matrix display at the front of the unit. A control button is
located on the rear of the unit. Push the control button firmly and evenly to operate.
4.1. TURNING ON
If external power is available, the unit will turn on
automatically when power is applied.
To turn the unit on when battery operated simply firmly
press and hold the control button until the COMPANY
LOGO appears on the display and then release, this
takes approximately 5 seconds.
The COMPANY LOGO will be displayed for 5 seconds
after power is applied or the button is released as shown
by the COUNTDOWN INDICATOR located at the lower
left corner of the display.
The COMPANY LOGO and subsequent start up screens
can be aborted by firmly pressing the CONTROL
BUTTON.
The next screen shows the PRODUCT LOGO and
firmware version.
The next screen shows 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 METHOD.
The unit now enters STABILISATION. During
STABILISATION the unit will not detect or log any
magnetic events and the LEDs will flash every 5
seconds. The remaining STABILISATION time is
displayed in HH:MM:SS format. When the
STABILISATION time reaches zero or the CONTROL
BUTTON is pressed, the unit will enter LISTENING
MODE. See section 4.2 STABILISATION for more
information.
While LISTENING, the screen will show the live
DIFFERENCE flux reading and the current number of
events logged along with the date and time of the most
recent event. The LEDs will flash every 5 seconds. See
section 4.3 LISTENING for more information.
COMPANY
LOGO
PRODUCT
LOGO
DATE & TIME
STABILISATION
LISTENING
PRESS/
TIMEOUT
PRESS/
TIMEOUT
PRESS/
TIMEOUT
PRESS/
TIMEOUT
APO STATUS
PRESS/
TIMEOUT
DETECTION
METHOD
PRESS/
TIMEOUT

4003_5001_D02 Page 8 of 35
4.2. STABILISATION
The STABILISATION delay occurs at switch ON only. During the STABILISATION delay the unit
will ignore all magnetic events. The LEDs will flash every 5 seconds and the relay and current
loop outputs will be in the DETECTION state. The STABILISATION delay can be used during
deployment to prevent any unwanted events from being logged due to movement of the unit in
the earths’ magnetic field and/or movement of nearby magnetic objects (such as vehicles).
The STABILISATION delay can be set to any value between 00:00:00 and 99:59:59 (in
HH:MM:SS format) using the CONTROL BUTTON or via the serial link. During the STABILISATION
delay a countdown timer is shown on the display, once this timer reaches 00:00:00 the unit will
start LISTENING. The STABILISATION delay can be bypassed by firmly pressing the CONTROL
BUTTON at any point during STABILISATION.
Remember that the STABILISATION delay occurs at switch ON only. If changes are made to the
STABILISATION delay setting then the unit should be turned OFF. The new STABILISATION delay
will occur whenever the unit is next turned ON.
4.3. LISTENING
Immediately after STABILISATION the unit will
display the LIVE DATA screen, similar to the screens
shown opposite.
If 0 events have occurred, this screen will show
E:00 with no date or time.
Once an event has occurred, this screen will show
the most recent EVENT number and the date and
time the event occurred. 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 will flash every 5 seconds, if enabled, and the
relay and current loop outputs will be in the LISTENING state. The unit continually takes RAW
flux readings which are FILTERED and the DIFFERENCE between the RAW and FILTERED values
calculated. If the DIFFERENCE exceeds the THRESHOLD setting, then the unit will enter
DETECTION MODE where an event will be signalled if the detection criteria is met. The following
events may interrupt the unit while in listening mode:
MAGNETIC EVENT –If a DIFFERENCE flux reading greater than the THRESHOLD value is
detected while the unit is LISTENING, the unit will enter DETECTION MODE once the detection
criteria has been met an EVENT will be signalled (discussed in section 4.4 DETECTION MODE).
CONTROL BUTTON –Firmly pressing and holding the CONTROL BUTTON momentarily (< 1
second) will enable the LIVE DATA screen for 10 seconds. Firmly pressing and holding the
CONTROL BUTTON for > 3 seconds will enter the MENU interface which is described in section
4.5 SINGLE BUTTON MENU INTERFACE of this manual.
SERIAL COMMAND –If a serial command is received via the serial data link then it will be
processed before the unit continues LISTENING.
LISTENING
0 EVENTS
LISTENING
12 EVENTS
LISTENING
DISPLAY OFF
OR
10 SEC
TIMEOUT

4003_5001_D02 Page 9 of 35
4.4. DETECTION MODE
There are two DETECTION METHODS. The default PIG PASS mode detects when the PIG has
likely to have PASSED the signaller and DETECTION ONLY detects the presence of a pig but not
necessarily that it has passed. The latter is useful when trying to determine when a PIG has
been launched, where the pig is initially present, and the pig’s movement will be away from the
signaller –i.e. will not create a flux peak.
4.4.1. PIG PASSED
Once the gauss reading crosses the threshold,
DETECTION starts, the pig state changes to PIG
APPROACH and the pig approach screen is shown. The
GAUSS reading shows the live gauss reading.
PIG PASSED is signalled when the flux reading has
peaked and fallen by a defined drop as specified by
the DETECTION CRITERIA, reference section 4.5.11
DETECTION METHOD. The larger the defined drop,
the more likely that the pig has passed the unit.
However, if the signaller is located close to the pig
receiver, then a smaller drop should be considered as
the pig’s magnetic signal may not fully clear the
signaller.
During DETECTION the display shows PIG nnn
PASSED and the LEDs around the display will flash
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), the data will be
logged but no event will be signalled. In this situation,
the pig has been detected but is likely to have stopped
before the signaller. If the pig then moves and passes
the signaller (providing the gauss value exceed the
THRESHOLD was far enough away to cause a peak –
otherwise the signaller will timeout again and log the
data), a PIG PASSED event is likely to be triggered If
the unit is in LP MODE, the screen will stay on until
DETECTION completes or the unit times out and
reverts to LISTENING where normal LP mode will
resume.
4.4.2. PIG DETECTION ONLY
Once the gauss reading crosses the threshold, DETECTION starts, the pig state changes to PIG
APPROACH and the pig approach screen is shown. The gauss reading shows the live gauss
reading.
THRESHOLD
EXCEEDED
PIG DETECTION
DETECTED ONLY
PRESS/
TIMEOUT
LISTENING
DISPLAY OFF
LISTENING
13 EVENTS
LISTENING
DISPLAY OFF
(LP MODE)
10 SEC
TIMEOUT
EVENT
TRIGGERED
OR
PIG APPROACH
PIG DETECTION
PASSED