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

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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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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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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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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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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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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.

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3.3.16. SET TRIG DELAY
Accessed from SETUP MODE 1. This option sets a time delay after detection. As the unit will
detect debris and gas being pushed in front of the PIG, the unit continues to monitor the pipe
for a PIG passage during the TRIG DELAY period. If a trigger is received during this time the
delay will be reset to ensure the recorded event time is more accurate.
3.3.17. SET FILTER
Accessed from SETUP MODE 1. If there is a poor signal path through the pipeline due to gas or
solids in the pipeline product then the FILTER value may be increased to avoid the possibility
of false triggers. It may be adjusted to any value from 001 to 255. See section 3.6 DETECTION
ALGORITHM for more information.
3.3.18. SET CONFIG
Accessed from SETUP MODE 1. The SET CONFIG menu allows the user to enable special
functions within the unit. The number the CONFIG option is chosen by adding up the values for
the desired options in the table below.
Option
Number
Effect when selected
Invert Relay Operation
1
Relay will be normally closed and will open when
signalling
Debug display
2
Displays information useful for debugging on the
OLED when something is detected in the pipe.
LED Flash disable
4
Disables the flashing LEDs while listening. The
LEDs will still flash when a PIG is detected
Rechargeable Battery
8
Enables unit to recognise rechargeable battery
fitted and to adjust battery monitor accordingly
For example if you want the relay option to be inverted and the LED flash disabled:
Number for inverting relay = 1
Number for Debug display = 0
Number for LED flash disable = 4
CONFIG number = 1 + 0 + 4 = 5
There for the number to be input to the CONFIG menu is 5.

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3.4. SETUP MODE 1
The figure below shows the flow diagram for SETUP MODE 1. This mode is used to configure
the units various parameters and calibrate the unit to a particular pipe.
The main screen shows the actual waveform which the unit is processing and examining. In
this mode the unit is shooting 10 times per second. The ‘pulse’ on the immediate left is the
transmit signal injected into the pipe and pulses to the right show the reflected signals from
the other side of the pipe. Using the ruler along the bottom of the screen you can see that the
first reflected signal in the above example occurs around 31cm from the injected pulse and this
is confirmed by the value highlighted as the DETECTED DIAMETER. This means that the unit is
installed on a pipeline with a 31cm diameter. As you can see from this example we are also
seeing a secondary echo and if we zoomed out further we would see further echoes gradually
dying away.
There are 3 events which will exit from this screen:
1. A short switch press will adjust gain, pulse width, or zoom level depending what the
SWITCH FUNCTION field contains.
2. A long switch press (held until screen goes blank) will enter the display menus.

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3.4.1. ZOOM AND RULER
The ruler along the bottom of the screen allows the user to visually measure the diameter of a
pipeline by observing the position of any reflections along the ruler. The user can select one of
4 zoom levels which will show rulers of length 40cm, 80cm, 160cm or 320cm. The zoom level
is cycled by applying a short press on the switch while the SWITCH FUNCTION field is Z.
3.4.2. THRESHOLD LEVELS
The horizontal lines are used to help calibrate the unit to a particular pipeline. The middle line
represents the THRESHOLD level of detection. To be detected a signal must cross this line. The
GAIN and PULSE WIDTH can be adjusted to make sure a signal crosses this threshold. The
position along the ruler where the first reflected signal crosses this line should match the value
shown in the DETECTED DIAMETER field. The upper and lower lines give a guide as to the best
minimum signal level and maximum noise level respectively.
3.4.3. DETECTED DIAMETER
This field shows the pipe diameter which the unit is detecting. This should be checked by
looking at the waveform and noting the position of the first reflection along the RULER. GAIN
and PULSE WIDTH can be adjusted to make the waveform cross the THRESHOLD level.
3.4.4. GAIN
The current GAIN is shown in this field and can have any value from 00-99.
An increase in gain will cause an increase in signal amplitude. To adjust the GAIN enter the
menus by pressing and holding the switch until the screen goes blank. Then cycle down to
ADJUST GAIN UP or ADJUST GAIN DOWN and let the counter reach zero. When the unit re-
enters the original screen the SWITCH FUNCTION field should contain G to tell the user that a
short switch press will increment or decrement the GAIN.
When the user applies a short switch press the GAIN field will increment or decrement and the
waveform should increase or decrease in amplitude. In this way a weak reflection can be made
to cross the THRESHOLD line and cause the correct DETECTED DIAMETER to be detected.
Once a suitable gain has been determined the value should be saved permanently by re-
entering the menus and selecting SAVE GAIN AND PW. If this step is not taken then when the
MODE is changed or the unit switched off the value will be lost.
3.4.5. PULSE WIDTH
The current PULSE WIDTH is shown in this field and can have any value from 00-09.
The effect of changing pulse width is not always predictable but generally a wider pulse width
will cause more power to be injected into the pipe and result in stronger reflections. Normally
the PULSE WIDTH is left at the default value 01 and GAIN adjusted to increase signal strength.
To set the PULSE WIDTH enter the menus by pressing and holding the switch until the screen
goes blank. Then cycle down to AJST PULSE WIDTH on the second menu page and let the
counter reach zero. When the unit re-enters the original screen the SWITCH FUNCTION field
should contain W to tell the user that a short switch press will increment the PULSE WIDTH.
When the user applies a short switch press the PULSE WIDTH field will increment and the
effect should be seen on the waveform. Once a suitable PULSE WIDTH has been found SAVE
GAIN AND PW should be selected to save the value. If this step is not taken then when the
MODE is changed or the unit switched off the value will be lost.

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3.4.6. SWITCH FUNCTION
The SWITCH FUNCTION field tells the user what a short switch press will do at any particular
moment. There are 3 alternatives: G, W, or Z which will alter GAIN, PULSE WIDTH, or ZOOM
respectively.
3.4.7. DETECT VALUE
The DETECT VALUE gives an indication of the quality of the signals which the unit is receiving.
Ideally the DETECT value should remain at 000 unless a pig passage is occurring when it
should immediately start to increase. Basically every time the unit does not see a reflection
from the back wall of the pipeline this value will be incremented. If this value every reaches a
value greater than the user adjustable value DETECTION COUNT the unit will assume a pig
passage. Note that in SETUP MODE 1 the unit is only transmitting through the pipeline 10
times per second, while in DETECTION MODE 0 it is transmitting 100 times per second. See
section 3.6 DETECTION ALGORITHM for more information.
3.5. BATTERY INDICATOR
The battery indicator is shown at the bottom right corner of most screens and gives the user
an indication of the battery status.
If CONFIG (see section 3.3.18 SET CONFIG) does not have the Rechargeable Battery option
enabled then all bars are displayed when the battery/external supply > 15 Volts. No bars are
displayed when the voltage < 11 Volts. If CONFIG is set to enable Rechargeable Battery option
then all bars are illuminated when the voltage > 13 Volts and are all off when the voltage <
10.5 Volts.

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3.6. DETECTION ALGORITHM
This section gives a brief description of the detection algorithm used to enable the user to
make more educated changes to the detection parameters. Refer to the figure below to
understand the basic decisions and actions which are taken to detect a pig passage. There are
basically 3 values of interest here:
1. DETECT is an internal value which is constantly changing depending on whether the unit
receives a reflection from the pipe wall or not. If a constant good signal from the far wall
of the pipe is present then this value will remain at zero. If this reflection is removed then
DETECT will begin to rise, if it reaches the same value as DETECT COUNT then a pig
passage will be signalled.
2. FILTER is a user adjustable value which can be set from 001 to 255. As can be seen this
value is subtracted from DETECT every time the unit receives a good reflection from the
far pipe wall. If a reflection is seen then it is assumed that a pig passage cannot be taking
place. If there is a poor signal path through the pipeline then increasing this value may
help.
3. DETECT COUNT is a user adjustable value which can be set from 001 to 255. If the unit is
not receiving reflections from the back wall of the pipeline then the DETECT value will be
increasing. If it ever reaches DETECT COUNT then a pig passage is signalled. If there is a
poor signal path through the pipeline then increasing this value may help.

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4. INSTALLATION
The Special Conditions for Safe Use detailed in section 9 ATEX APPENDIX must be observed
and followed at all times.
In order to effectively install and calibrate the unit to a particular pipeline the pipeline should
be filled with an acoustically transparent fluid at the time of installation (single phase, no gas
bubbles, no large solid particles).
Because the transducer is permanently connected to the main housing via a cable and the
transducer is screwed into contact with the pipeline some precautions must be taken to avoid
the cable becoming excessively twisted. The figure below shows the preferred mounting
positions for the system.
4.1. MAIN HOUSING INSTALLATION
1. Referring to the figure above fit the main housing mounting plate onto the main housing
mounting block with 4xM8x35 CAP screws and washers.
2. Fit the main housing onto the mounting plate with 2xM8x25 CAP screws, washers, and
NYLOC nuts.
3. With the help of another person sit the main housing assembly on the pipeline at a
suitable location and using the provided straps securely tighten the assembly onto the
pipeline.
4. Connect the earth stud on top of the main housing to a suitable earth bonding point at the
point of installation.

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4.2. TRANSDUCER INSTALLATION
1. For optimum results ensure that the pipeline surface at the point of installation is uniform,
clean and smooth. If the surface is irregular, corroded, or has flaking paint then abrasive
paper or a wire brush should be used to prepare the surface. The unit will operate
effectively through most painted layers as long as they are clean, uniform and are fully
bonded to the pipeline surface. The unit will not operate through layers which are not
bonded well to the pipeline surface, coatings which contain air gaps, foam coatings,
concrete coatings, insulated coatings, or composite coatings consisting of several different
materials with different densities. In these cases remove an area of the coating and install
the transducer directly onto the bare pipeline surface.
2. Before the transducer mounting block is strapped to the pipeline screw it onto the
transducer until the transducer is barely touching the pipeline surface when the transducer
assembly is pressed onto the pipeline. This should mean that when strapped to the
pipeline it should take less than one turn to securely press the transducer face onto the
pipeline surface.
3. Apply couplant to the centre of the transducer face and to the area of pipeline surface
where the transducer is to be installed.
4. Securely strap the transducer assembly onto the pipeline surface so the transducer is
transmitting horizontal. If it is mounted vertically and there is a significant amount of gas
in the pipeline fluid then this will tend to float up to the top of the pipe and disturb the
signal path through the pipeline.
5. Make sure the transducer mounting block is sitting securely on the pipeline so that the
transducer is held perpendicular to the pipeline surface. If the transducer is engaged too
far into its mounting block then you may need to loosen it slightly to allow the mounting
block to sit properly on the pipe surface.
6. When happy with the transducer mounting block installation hand tighten the transducer
itself onto the pipeline surface. Do not tighten excessively, just enough so that it is secure,
otherwise the transducer face may be damaged. If more than 1 full turn is required to
tighten the transducer then repeat the above procedure from step 2.
7. Tighten the transducer locking screw to prevent the transducer from turning. Do not
tighten excessively as the mounting block may be damaged.

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4.3. PARAMETER SETUP
Every time the unit is installed on a pipeline this setup procedure should be followed. For the
following example let’s assume we know the external diameter of the pipe is 24” so we should
expect to see a detected diameter of around 61cm.
1. With the unit mounted on the pipeline switch to SETUP
MODE 1. We see the screen to the left. Notice the strong
transmit pulse and a weak reflection at 60cm –we know
we are working on a 60cm diameter pipe. The signal is
too weak as it does not cross the threshold level (middle,
horizontal line) so the diameter is not being detected.
We will increase gain until it is well over this level.
2. After increasing gain, notice that when the signal crosses
the threshold level (middle, horizontal line) the correct
diameter is detected. It would be enough to leave the
unit as it is now however there are some spurious signals
immediately before the main reflection which cross the
maximum noise level (bottom horizontal line). We may
be able to reduce these by varying the pulse width.
3. After varying the pulse width we have found the position
at which the reflected signal is proportionally largest
compared to the spurious signals before it. However, the
overall signal strength has reduced to below the
minimum signal level (top horizontal line) so we need to
turn up gain again.
4. After increasing the gain notice we now have a good
strong signal well above the threshold level (middle
horizontal line), the maximum signal level is above the
minimum signal level and the spurious signals are well
below the maximum noise level. Also we can see the
detected diameter reflects the position of the first
reflection along the ruler. It may be necessary to
readjust gain and pulse width a few times to iteratively
reach these optimum settings.
5. Once the optimum settings have been determined select SAVE GAIN AND PW from the
display menu to save the settings. If this step is omitted then the settings will be lost next
time the mode is changed or the unit is switched off.
6. Set DETECT COUNT as per section 3.3.11 SET DETECT COUNT.
7. Set INDICATOR DELAY as per section 3.3.12 SET INDICATOR DELAY.
8. Set MINIMUM DIAMETER as per section 3.3.13 SET MINIMUM DIAMETER.
9. Return to DETECTION MODE 0 and ensure that after the DETECTING DIAMETER… message
the correct pipe diameter is displayed and that the signal quality is over 95%. The unit will
then start waiting for a pig passage. If this is not the case re-enter SET UP MODE 1 and
adjust settings as necessary.

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5. RECOMMENDED MAINTENANCE
The Special Conditions for Safe Use detailed in section 9 ATEX APPENDIX must be observed
and followed at all times.
Frequent inspections should be made. A schedule for maintenance checks should be generated
according to the environment and frequency of use but should be regular enough to ensure the
equipment continues to operate in the designed manner. It is recommended that it should be
at least once a year.
External parts of the equipment should be periodically cleaned using fresh water to ensure that
deposits are not allowed to accumulate. Avoid the use of aggressive chemicals.
Check flame paths / threads on the enclosure body and lid for signs of corrosion or damage. If
badly pitted or damaged, replace the relevant component.
The unit contains a coin cell (BR2032) used to power the Real Time Clock (RTC) circuitry which
provides system date and time. This battery should be replaced every 5 years.
All components that are replaced must be in accordance with the manufacturers’ specifications.
Failure to use such components may invalidate the certification/approval and may make the
equipment dangerous.
5.1. MAIN BATTERY REPLACEMENT
1. The Special Conditions for Safe Use detailed in section 9 ATEX APPENDIX of this manual
must be observed and followed at all times.
2. Referring to the figure below use a 3mm AF Hex key to loosen the locking GRUB SCREW
which locks the main housing lid shut. Unscrew and remove the lid to expose the
electronics and display.
3. Using a 3mm AF Hex key remove the 4x M4x12 cap screws holding the main PCB down
and then carefully lift off the main PCB to reveal the battery pack. Place the main PCB
somewhere safe where it will not be accidentally damaged while the battery pack is being
replaced. Note the position of the RTC cell behind the display.
4. Note the orientation of the battery with the two metal contacts on the same side as the
button and cable entries as shown in the figure above.
5. Re-assemble the unit following these instructions in reverse. When replacing the main PCB
ensure it is located properly using the dowel pins provided. Ensure that all PCB
connections mate properly. Do not over tighten the locking GRUB SCREW.

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6. EXTERNAL CONNECTIONS
The Special Conditions for Safe Use detailed in section 9 ATEX APPENDIX of this manual must
be observed and followed at all times.
A suitable cable and ATEX certified gland must be provided by the user. A suitable gland to use
with a non-mineral filled cable would be a Peppers Cable Glands Limited CR-XSCK1/20S/M20
barrier gland. A single M20x1.5 threaded entry is provided as standard. The cable cores should
have a length of approximately 150mm inside the unit to allow for ease of connection.
Unless the unit has been ordered with a battery
pack the unit will be delivered with a 4mm2
TERMINAL BLOCK and PARTITION PLATE already
fitted inside the battery compartment as shown.
If the unit is to be connected to any external
circuitry such as an external power supply or
SCADA system then the unit must be fitted with a
PARTITION PLATE and the main battery must be
removed.
Remove the lid and main PCB to gain access to the
battery compartment as described in section 5.1 MAIN BATTERY REPLACEMENT.
If a TERMINAL BLOCK and PARTITION PLATE are fitted already then the unit is ready for
connecting external circuits.
If a TERMINAL BLOCK and PARTITION PLATE are not fitted then follow the instructions below
to fit them.
1. Observe how the wires connected to the transducer cable are routed inside the housing
before removing the 2x M4x25 cap screws holding the plastic battery compartment in place
and carefully withdrawing the entire assembly out of the main housing. While withdrawing
the battery compartment be very careful not to damage any existing wiring.
2. Observe how the transducer cable is connected to the assembly and then disconnect.
3. To fit the TERMINAL BLOCK, terminate the wires to the TERMINAL PCB as per section 6.1
STANDARD TERMINAL PCB.
4. While in LISTENING state the current loop output shall be 5mA ±1.mA. While in DETECTION
the current loop output shall be 19mA ±1.mA.
5. To fit the PARTITION PLATE simply slot into position in the battery compartment and lock
into place using the 2mm dowels provided.
6. Re-connect the transducer cable and then carefully re-fit the battery compartment inside
the housing. While refitting the battery compartment be very careful not to damage any of
the wiring by initially positioning the wiring so that it points straight down into the housing
until the wiring has passed the housing lip and then repositioning the wiring from inside the
compartment so that it passes along one of the slots on the bottom of the battery
compartment. Ensure all wiring is safely located inside the enclosure and is not trapped
under the battery compartment
7. Secure the battery compartment with the 2x M4x25 cap screws.
8. Refer to section 6.1 STANDARD TERMINAL PCB to make the required external connections.