Online Electronics ID5000A User manual

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CHALLENGE
ACCEPTED
Non-Intrusive Signaller
Ultrasonic Active Topside
Operating Manual
The ID5000A is a fully ATEX certified,
non-intrusive pig signaller which detects,
signals and logs the passage of pigs at
critical points along the pipeline both on land
and off shore

ONLINE ELECTRONICS LTD
ID5000A_5001_A03 Page 1 of 21
ID5000A_5001
Rev
Date
By
Summary of change
A00
08/08/17
BG
CR00485: Was ID5000A MANUAL RevB02. CR00380: Address change.
CR00499: Front cover update.
A01
12/10/17
BG
CR00499: Cover page update
A02
28/07/20
TL
CR00800: Email address and Notified Body Number updated.
A03
15/10/20
TL
CR00947: New Front Page. Section 9 updated.
COMMENTS:

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ID5000A_5001_A03 Page 2 of 21
CONTENTS Page
1. GENERAL DESCRIPTION ......................................................................................... 3
2. SYSTEM SPECIFICATION ........................................................................................ 4
3. OPERATION .......................................................................................................... 5
3.1. TURN ON SEQUENCE.......................................................................................... 5
3.2. DETECTION MODE 0 .......................................................................................... 6
3.3. SINGLE BUTTON MENU INTERFACE...................................................................... 7
3.3.1. STATUS ........................................................................................................ 7
3.3.2. VIEW EVENTS ............................................................................................... 7
3.3.3. DELETE ALL EVENTS ...................................................................................... 8
3.3.4. MODE1 SETUP ............................................................................................... 8
3.3.5. SHUTDOWN .................................................................................................. 8
3.3.6. SAVE GAIN AND PW ....................................................................................... 8
3.3.7. MODE0 DETECT ............................................................................................. 8
3.3.8. ADJUST GAIN UP ........................................................................................... 8
3.3.9. ADJUST GAIN DOWN...................................................................................... 8
3.3.10. AJST PULSE WIDTH........................................................................................ 8
3.3.11. SET DETECT COUNT....................................................................................... 9
3.3.12. SET INDICATOR DELAY .................................................................................. 9
3.3.13. SET MINIMUM DIAMETER................................................................................ 9
3.3.14. SET TIME...................................................................................................... 9
3.3.15. SET DATE ..................................................................................................... 9
3.3.16. SET TRIG DELAY.......................................................................................... 10
3.3.17. SET FILTER ................................................................................................. 10
3.3.18. SET CONFIG................................................................................................ 10
3.4. SETUP MODE 1................................................................................................ 11
3.4.1. ZOOM AND RULER ....................................................................................... 12
3.4.2. THRESHOLD LEVELS .................................................................................... 12
3.4.3. DETECTED DIAMETER .................................................................................. 12
3.4.4. GAIN.......................................................................................................... 12
3.4.5. PULSE WIDTH ............................................................................................. 12
3.4.6. SWITCH FUNCTION...................................................................................... 13
3.4.7. DETECT VALUE ............................................................................................ 13
3.5. BATTERY INDICATOR ....................................................................................... 13
3.6. DETECTION ALGORITHM................................................................................... 14
4. INSTALLATION .................................................................................................... 15
4.1. MAIN HOUSING INSTALLATION ......................................................................... 15
4.2. TRANSDUCER INSTALLATION............................................................................ 16
4.3. PARAMETER SETUP .......................................................................................... 17
5. RECOMMENDED MAINTENANCE ............................................................................. 18
5.1. MAIN BATTERY REPLACEMENT........................................................................... 18
6. EXTERNAL CONNECTIONS .................................................................................... 19
6.1. STANDARD TERMINAL PCB ............................................................................... 20
7. WARRANTY ......................................................................................................... 20
8. DISPOSAL OF UNIT.............................................................................................. 20
9. ATEX APPENDIX .................................................................................................. 21

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ID5000A_5001_A03 Page 3 of 21
1. GENERAL DESCRIPTION
The ID5000A (Active) Ultrasonic pig signaller is a fully ATEX certified, non-intrusive, pig
signaller which detects, signals, and logs the passage of pigs at critical points along fluid filled
pipelines both on land and offshore.
The signaller uses the pulse-echo method to detect the time of flight of ultrasonic pulses
through the pipe. An ultrasonic pulse is sent through the pipe wall and provided that an
acoustically transparent column of fluid is passing through the pipe (single phase, no gas
bubbles, no large solid particles), the unit is able to see a “reflection” of energy from the other
side of the pipe. When a pig passes, the fluid path is disturbed, removing the reflection, and
the pig is detected.
Events are signalled as they occur via a 2.7” graphical display and high brightness LEDs
positioned around the perimeter of the display. Events can also be signalled remotely using
several optional outputs.
The unit logs the time and date of up to 100 events which can be viewed at any point using
the local display. The user can turn the unit ON and OFF as well as modify several settings
using a single control button and intuitive menu system.
The unit has two basic parts as shown below. The transducer is permanently connected to the
main housing via a cable. The transducer is screwed into a mounting block which can be
quickly and easily attached to the pipeline using ratchet straps or steel banding. The main
housing contains all electronics, battery (if fitted), display and the control button. The main
housing is mounted onto the pipeline using a mounting block and straps in a similar fashion to
the transducer.

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ID5000A_5001_A03 Page 4 of 21
2. SYSTEM SPECIFICATION
GENERAL
Battery Type .....................................................15V Alkaline Non-Rechargeable Battery Pack
Battery life LISTENING at +20°C (from 15V Alkaline Non-Rechargeable Pack)............ 120 Days
Rechargeable Battery Type ........................................... 12V NiMH Rechargeable Battery Pack
Battery life LISTENING at +20°C (from 12V NiMH Rechargeable Battery Pack).............12 Days
External Supply................................................................................................... 24.0VDC
Ambient Temperature Range .................................................. See section 9 ATEX APPENDIX
ATEX Code.................................................................................. II 2 G Ex d mb IIC T5…T6
EC Type Examination Certificate Number ................................................. TRL08ATEX21161X
Housing Material (SS Unit Only) ............................................................316L Stainless Steel
Housing Material (Al Unit Only) .................................. Copper Free Aluminium Alloy LM25 (Al)
Transducer Material .............................................................................316L Stainless Steel
Weight in Stainless Steel ........................................................................................... 15kg
Weight in Aluminium.............................................................................................. 11.5kg
OUTPUTS
SPDT Relay Outputs (Volt Free Contacts).................................2A @ 30VDC / 0.5A @ 125VAC
Current Loop Output ................. 5.0mA ±1.0mA (LISTENING) / 19.0mA ±1.0mA (DETECTION)
Logging .............................................................................. 100 Events with Time and Date

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ID5000A_5001_A03 Page 5 of 21
3. OPERATION
The Special Conditions for Safe Use detailed in section 9 ATEX APPENDIX must be observed
and followed at all times.
3.1. TURN ON SEQUENCE
To turn the unit on simply press and hold the control
button until the company logo appears on the display
and then release, this takes approximately 5 seconds.
The next screen shows the product logo. This screen
will be displayed for 5 seconds as shown by the
counter at the bottom left corner of the display.
When the countdown indicator at the bottom left of
the screen reaches zero, or the control button is
pressed, the next screen will appear.
The next screen shows the time and date currently
set in the unit.
The next screen indicates that the unit is trying to
detect the pipe diameter. While this screen is visible
the unit is shooting ultrasound into the pipe several
hundred times per second and from the received
reflections is calculating the diameter. A switch press
at this stage will have no effect. After the unit is
finished it will display the DETECTED DIAMETER
screen.
The distance in the centre of this screen shows the
average diameter which the unit detected. The next
line gives an idea of the quality of this signal path
between 00-99%. The measured diameter should be
very close to the external diameter of the pipeline but
will vary slightly due to pipe wall thickness and the
type of fluid in the pipe. Factors which could cause a
poor signal quality include how well the transducer is
coupled to the pipe surface, foreign particles within
the pipe fluid, gas bubble within the pipe fluid or non-
uniform pipe wall material.
While on the DETECTED DIAMETER screen, to re-
detect the pipe diameter, the switch can be pressed
before the counter reaches zero. If the counter
reaches zero the unit will enter DETECTION MODE 0.
See section 3.2 DETECTION MODE 0.
PRESS/
TIMEOUT
PRESS/
TIMEOUT
PRESS/
TIMEOUT
DE TECT ED DI AM ETER
028cm
GO OD SI GNAL 99%
3 PR ES S TO RE SE T
15:34:55
28/04/15
3
DETECTING DIAMETER…
ID5000
PIG DETECTOR
5
5
PRESS
DETECTION
MODE 0
TIMEOUT
TIMEOUT

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ID5000A_5001_A03 Page 6 of 21
3.2. DETECTION MODE 0
Whilst in DETECTION MODE 0 nothing is visible on the display itself however the LEDs around
the perimeter of the window will flash once every 5 seconds to indicate that the unit is alive
and waiting in this mode for a pig passage. There are 2 events that will cause the unit to react:
PIG DETECTION: If a pig passage occurs then the unit will immediately log the event time
and date to its internal memory. It will then turn the display on and show a PIG DETECTED
message with event time and date. The LEDs will start flashing every second to give a long
range indication of the pig passage.
The length of time which the unit keeps indicating the pig passage in this way is determined by
the INDICATOR DELAY value. See section 3.3.12 SET INDICATOR DELAY for a description of
this parameter and how to alter its value.
SWITCH PRESS: A single, short press of the switch will enter the display menu interface
described in section 3.3 SINGLE BUTTON MENU INTERFACE.
If the unit is not properly calibrated to a pipeline then it may repeatedly signal a PIG
DETECTED message. If this is the case then while the pig passage is being signalled press the
switch once then immediately press again and hold for approximately 3 seconds. This will enter
the display menu where SETUP MODE 1 should be selected and then refer to section 4.3
PARAMETER SETUP to calibrate the unit to the pipeline.
DE TECT ED DI AM ETER
028cm
GO OD SIGN AL 99%
3 PR ES S TO RE SE T
DETECTING DIAMETER…
PL EASE M AKE SELECTION
=> EXIT
ST AT US
VI EW EVENTS
DE LE TE ALL E VENTS
MO DE 1 SET UP
SH UT DO WN
4
PRESS
DETECTION
MODE 0
TIMEOUT
TIMEOUT
EXIT
PRESS
PIG
DETECTED
15 :45: 55 28/04/15
PRESS/
TIMEOUT

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ID5000A_5001_A03 Page 7 of 21
16 :08: 55 28/ 04/15
PI PE DIAM ET ER 02 8cm
ST ORED EVEN TS 009
LS T 28 /04/ 15 16: 00:05
ST ORED G AIN 99
IN D DELAY 00: 10:59
DE TECT ION C OU NT 50
4
28 /04/ 15 16: 08:55
EVENT064
28/04/15
16:00:05
5
3.3. SINGLE BUTTON MENU INTERFACE
While in DETECTION MODE 0, the control button can be pressed at any point to enter the
menu interface. While in the menu interface, the unit will ignore all pig passages. From the
menus the user can configure several parameters which are discussed in this section.
To enter the menu interface from SETUP MODE 1 a long press on the control button is required
as per section 3.4 SETUP MODE 1.
Note that the menus entered from DETECTION MODE 0 and SETUP MODE 1 contain different
items. All items are covered by the following sections and each section indicates whether the
item is accessed from DETECTION MODE 0 or SETUP MODE 1.
While in the menu system, every time the user presses the control button the => cursor will
move down one line and the timer at the bottom left of the screen will be reset to 5. Once the
cursor is pointing at the desired item the user simply allows the timer to reach 0 and the
selected item will be executed. This simple behaviour is used throughout the menu interface to
modify settings and interact with the unit.
To modify parameters, simply follow the instructions provided on the screen. All parameters
are incremented by pressing the control button until they are at the desired value then
allowing the timer to reach 0.
If you do not wish to modify a parameter then simply allow the timer to reach 0 without
operating the control button. The menu system is designed so that the unit will always EXIT if
the control button is left released for a long enough time.
3.3.1. STATUS
Accessed from DETECTION MODE 0. Selecting this item
shows current time and date, pipe diameter detected, the
number of stored events, the date and time of the last
event, stored gain value, current indicator delay, and the
detection counter setting.
When the counter indicator reaches zero the screen will go
blank and the unit will start looking for a pig passage
again. If the user wants to pause the screen to read it they can press and hold the switch to
pause the timer.
3.3.2. VIEW EVENTS
Accessed from DETECTION MODE 0. Selecting this item
allows the user to scroll through logged event data. If no
data has been logged then a NO EVENTS message will be
displayed.
The events are displayed one at a time from newest to
oldest. At the very top of each display the current date and
time are shown. Below this the event number is shown with
the event date and time. If the switch is pressed before the counter reaches zero the screen
will show the next event. If the counter reaches zero then the display will switch off and the
unit will return to DETECTION MODE 0.

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ID5000A_5001_A03 Page 8 of 21
3.3.3. DELETE ALL EVENTS
Accessed from DETECTION MODE 0. Selecting this item will display the message *WARNING*
PRESS TO ERASE ALL EVENTS. If the user wishes to delete all logged data then they should
press the switch once before the counter reaches zero. If they do not wish to erase all logged
data then simply allow the counter to reach zero without pressing the switch.
3.3.4. MODE1 SETUP
Accessed from DETECTION MODE 0. Selecting this item leaves DETECT MODE 0 and enters
SETUP MODE 1. See section 3.4 SETUP MODE 1.
3.3.5. SHUTDOWN
Accessed from DETECTION MODE 0. Selecting this item switches off the unit. When the
counter reaches zero the display will go blank and the LEDs will flash once. All logged events
and parameters will still be available when the unit is next switched on.
3.3.6. SAVE GAIN AND PW
Accessed from SETUP MODE 1. This saves the current GAIN and PULSE WIDTH values
configured from within SETUP MODE 1. This should be done whenever any changes are made
to the GAIN and PULSE WIDTH values from within SETUP MODE 1 which are to be stored. If
this is not done then any changes to GAIN and PULSE WIDTH will be lost if SETUP MODE 1 is
exited.
3.3.7. MODE0 DETECT
Accessed from SETUP MODE 1. Selecting this item leaves SETUP MODE 1 and enters DETECT
MODE 0. If the SAVE GAIN AND PW item was not selected prior to this then any changes to
their values will not be saved.
3.3.8. ADJUST GAIN UP
Accessed from SETUP MODE 1. This item changes the function of the switch to increment
GAIN. The unit will return to SETUP MODE 1 after choosing this option and every short press of
the switch will increment the gain value. Once GAIN is set the SAVE GAIN AND PW option
should be selected.
3.3.9. ADJUST GAIN DOWN
Accessed from SETUP MODE 1. This item changes the function of the switch to decrement
GAIN. The unit will return to SETUP MODE 1 after choosing this option and every short press of
the switch will decrement the gain value. Once GAIN is set the SAVE GAIN AND PW option
should be selected.
3.3.10. AJST PULSE WIDTH
Accessed from SETUP MODE 1. This item changes the function of the switch to adjust PULSE
WIDTH. The unit will return to SETUP MODE 1 after choosing this option and every short press
of the switch will increment the pulse width value. Once the pulse width is set the SAVE GAIN
AND PW option should be selected.

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ID5000A_5001_A03 Page 9 of 21
3.3.11. SET DETECT COUNT
Accessed from SETUP MODE 1. DETECT COUNT controls how easy or hard it is for the unit to
be triggered. It is available as a setting to allow the unit to discriminate between a pig passage
and a spurious loss of signal caused by for example gas bubbles passing the transducer. The
unit transmits 100 pulses through the pipe every second. If DETECT COUNT is set to 01 then if
one of these pulses does not get reflected back then a pig passage is assumed. If DETECT
COUNT is set to 255 then 255 consecutive pulses would have to be missed before a pig
passage is assumed, meaning the signal was removed for 2.55 seconds. The table below
shows recommended values for a range of pipe sizes assuming a spherical pig (i.e. worst
case) with speed of 10 metres per second or 1 metre per second. See section 3.6 DETECTION
ALGORITHM for more information.
PIPE DIAMETER
DETECT COUNT
(PIG SPEED 10m/s)
DETECT COUNT
(PIG SPEED 1m/s)
6” (15.24cm)
1
15
12” (30.48cm)
3
30
24” (60.96cm)
6
60
36” (91.44cm)
9
90
48” (121.92cm)
12
120
3.3.12. SET INDICATOR DELAY
Accessed from SETUP MODE 1. This parameter determines how long the unit will signal a PIG
DETECTION for. See section 3.2 DETECTION MODE 0.
The INDICATOR DELAY can be set between 00:00:00 and 99:99:99 in HH:MM:SS format. Note
that the time entered will be the time that the LEDs will flash every second for. The seconds
field will be the total number of seconds which the display shall show the pig detection time
and date for. E.g. if INDICATOR DELAY is set to 01:59:60 the unit will flash every second for 2
hours and for the first 60 seconds of this time it will show the pig passage time and date on
the display.
3.3.13. SET MINIMUM DIAMETER
Accessed from SETUP MODE 1. The MINIMUM DIAMETER value determines how long the unit
shall wait for after it transmits a pulse before it looks for a reflection. Basically it allows the
user to force the unit to ignore any spurious signals which take place between the transmit
pulse and the reflected signal.
The first signal received after the MINIMUM DIAMETER value which has amplitude greater than
the threshold level shall be measured and if it is within 2cm of the pipe diameter a ‘good’
reflection will be assumed. Normally a minimum echo value which is approximately 33% of the
pipeline diameter will be sufficient. E.g. is pipe is 30cm diameter then a value of 10cm for
MINIMUM DIAMETER will suffice.
If the transmit pulse is not dying away quick enough or there are significant spurious echoes
present then choosing a larger MINIMUM DIAMETER value may be required but it should never
be set within 6cm of the actual pipe diameter.
3.3.14. SET TIME
Accessed from SETUP MODE 1. This option allows the user to set the internal system time.
3.3.15. SET DATE
Accessed from SETUP MODE 1. This option allows the user to set the internal system date.