Online Electronics ID5000P User manual

ONLINE ELECTRONICS LTD
ID5000P_5001_A01 Page 1 of 18
Online Electronics Ltd
Online House
Blackburn Business Park
Woodburn Road, Blackburn
Aberdeen
AB21 0PS
UK
[phone]
www.online-electronics.com
[email protected]
NON-INTRUSIVE SIGNALLER
ULTRASONIC PASSIVE TOPSIDE
OPERATING MANUAL
The ID5000P is a fully ATEX certified, non-intrusive pig
signaller which detects, signals and logs the passage
of pigs at critical points along a pipeline both on land
and offshore

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ID5000P_5001_A01 Page 2 of 18
ID5000P_5001
Checked
(IF APPLICABLE)
Date
(IF APPLICABLE)
Approved
Date
Rev
Date
By
Summary of change
A00
07/08/17
BG
CR00485: Was ID5000P MANUAL RevB04. CR00380: Address change.
CR00499: Front cover update.
A01
14/10/17
BG
CR00499: Cover page update
COMMENTS:
ca , 12:54:27, 12/10/2017

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ID5000P_5001_A01 Page 3 of 18
CONTENTS Page
1. GENERAL DESCRIPTION ......................................................................................... 4
2. SPECIFICATIONS ................................................................................................... 5
3. OPERATION .......................................................................................................... 6
3.1. INSTALLATION .................................................................................................. 6
3.1.1. MAIN HOUSING INSTALLATION ....................................................................... 6
3.1.2. TRANSDUCER INSTALLATION .......................................................................... 6
3.2. TURN ON SEQUENCE.......................................................................................... 7
3.3. LISTENING MODE .............................................................................................. 8
3.4. DETECTION MODE ............................................................................................. 8
3.5. RELAY OUTPUT.................................................................................................. 8
3.6. CURRENT LOOP OUTPUT..................................................................................... 9
3.7. SINGLE BUTTON MENU INTERFACE...................................................................... 9
3.7.1. EXIT........................................................................................................... 10
3.7.2. STATUS ...................................................................................................... 10
3.7.3. VIEW EVENTS ............................................................................................. 10
3.7.4. DELETE ALL EVENTS .................................................................................... 10
3.7.5. SHUTDOWN ................................................................................................ 10
3.7.6. MORE…....................................................................................................... 10
3.7.7. SET OUTPUT ............................................................................................... 11
3.7.8. SET TIME/DATE ........................................................................................... 11
3.7.9. LIVE DISPLAY ON/OFF .................................................................................. 12
3.7.10. SET FILTERS ............................................................................................... 12
3.7.11. SET LIMITS ................................................................................................. 12
3.7.12. SET COEFFICIENTS ...................................................................................... 12
3.7.13. FACTORY RESET .......................................................................................... 12
4. RECOMMENDED MAINTENANCE ............................................................................. 13
4.1. MAIN BATTERY REPLACEMENT........................................................................... 13
5. EXTERNAL CONNECTIONS .................................................................................... 14
5.1. STANDARD TERMINAL PCB ............................................................................... 15
5.2. HEATER PCB OPTION ....................................................................................... 15
5.3. MODBUS PCB OPTION ...................................................................................... 16
6. WARRANTY ......................................................................................................... 17
7. DISPOSAL OF UNIT.............................................................................................. 17
8. ATEX APPENDIX .................................................................................................. 18

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1. GENERAL DESCRIPTION
The ID5000P (Passive) pig signaller is a fully ATEX certified, non-intrusive, pig signaller which
detects, signals, and logs the passage of pigs at critical points along a pipeline both on land
and offshore.
The unit uses Passive (listening) techniques to detect pig passage events. 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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ID5000P_5001_A01 Page 5 of 18
2. SPECIFICATIONS
GENERAL
Battery Type .....................................................15V Alkaline Non-Rechargeable Battery Pack
Battery life LISTENING at +20°C (from 15V Alkaline Non-Rechargeable Pack)..............78 Days
Rechargeable Battery Type ........................................... 12V NiMH Rechargeable Battery Pack
Battery life LISTENING at +20°C (from 12V NiMH Rechargeable Battery Pack) .............40 Days
External Supply................................................................................................... 24.0VDC
Main Housing Ambient Temperature Range (External Power) ....................... -20°C to +85°C *
Main Housing Ambient Temperature Range (Alkaline Batteries) .................... -20°C to +54°C *
Main Housing Ambient Temperature Range (NiMH Rechargeable Batteries) .... -20°C to +65°C *
Transducer Ambient Temperature Range ................................................... -40°C to +85°C *
Maximum Pipeline Surface Temperature ............................................................... +150°C *
ATEX Code.................................................................................... II 2 G Ex d ib 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
* See 8 ATEX APPENDIX and 3.1 INSTALLATION instructions for full specifications.

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3. OPERATION
The Special Conditions for Safe Use detailed in section 8 ATEX APPENDIX of this manual must
be observed and followed at all times.
3.1. INSTALLATION
The unit can be installed by the end user, but the configuration and final set-up will require the
attendance of a representative from manufacturer, unless otherwise agreed.
For optimum results, the unit should be installed in the middle of a straight section of pipeline
at least 10m long. Sources of vibration, bends, valves and other pipeline features will alter the
expected acoustic signature of passing pigs and should be avoided. Drawings outlining the
proposed location of the unit should be provided to the manufacturer for review and comment
at the initial stage of any request. Contact manufacturer for further advice regarding suitable
installation checks.
If pipeline surface temperature is greater than +85°C then the main housing must not be
mounted on the pipeline and the sensor must be mounted on the lower half of the pipeline to
prevent convective heating. The sensor can be mounted on pipelines with surface temperature
up to +150°C assuming that ambient air temperature does not exceed +60°C.
3.1.1. MAIN HOUSING INSTALLATION
1. 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 main housing assembly to the
pipeline. Alternative mounting arrangements (such as pole mounted) can be specified at
time of order.
2. If required, connect the earth stud on top of the housing to a suitable earth bonding point at
the point of installation.
3.1.2. 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 an
abrasive paper or 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, however in the case of surface coatings which contain air
gaps, foam coatings, concrete coatings, thermally insulating coatings or composite coatings
consisting of several materials with different densities, an area of coating should be
removed to allow the installation of the Transducer directly onto the bare pipeline surface.
Contact manufacturer for further advice if there are any doubts.
2. Before the transducer mounting block is strapped to the pipeline, screw the transducer into
the transducer mounting block so that it will require less than one full turn to securely press
the transducer face to the pipeline surface when mounted. Care must be taken to avoid
excessively twisting of the cable between the transducer and the main housing.
3. Securely strap the transducer assembly onto the pipeline ensuring that the transducer is
held perpendicular to the pipeline surface.
4. Hand tighten the transducer firmly onto the pipeline surface. Using excessive force may
damage the transducer. If more than one full turn is required to tighten the transducer,
repeat the above procedure from step 2. Tighten the locking screw to prevent the
transducer from turning. Using excessive force may damage the mounting block.

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3.2. 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 and
firmware version at the bottom of the screen in Vxx
format. This screen will be displayed for 5 seconds
as shown by the COUNTDOWN INDICATOR at the
bottom left corner of the display.
When the COUNTDOWN INDICATOR 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. This can be changed if required. See
Section 3.7.8 SET TIME/DATE for more information.
The next screen is the STATUS screen. This screen
shows the current configuration of several settings.
See section 3.7.2 STATUS for more information.
The unit now enters STABILISATION. During
STABILISATION the unit will not detect or log any
magnetic events. When the COUNTDOWN reaches
zero or the control button is pressed the unit will
enter LISTENING MODE.
The final screen shows the unit in LISTENING
MODE. The 8 LEDs will flash once every five seconds
while the unit waits for a pig passage. See Section
3.3 LISTENING MODE for more information.

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3.3. LISTENING MODE
While in LISTENING mode the unit continuously monitors the sound energy produced by the
pipeline as it waits for a pig passage to occur. The display shall be off and the LEDs around the
perimeter of the display will flash every five seconds. The relay and current loop outputs will
be in LISTENING state. There are two things that may cause this screen to change:
PIG PASSAGE –The unit is configured to recognize the unique sound signature produced by a
pig as it passes under the transducer. If the unit detects a pig passage then the unit will show
a PIG DETECTED message as per section 3.4 DETECTION MODE.
CONTROL BUTTON –Pressing the control button while the display is turned off will enter the
DISPLAY MENU interface which is described in section 3.7 SINGLE BUTTON MENU INTERFACE.
3.4. DETECTION MODE
When a pig is detected the display will show a PIG DETECTED
message and the time and date of the event as shown. The
LEDs around the perimeter of the display will flash every
second and the relay and current loop will be in the
DETECTION state. The time and date of the pig passage are
stored in internal memory and can be viewed later using the
menu interface.
The length of time the unit will remain in this state for is determined by the OUTPUT DELAY
value. See section 3.7.7 SET OUTPUT for a description of this parameter and how to alter its
value. It should be configured to give the pig enough time to get out of the range of the sensor
after it has been detected to avoid re-trigger. When dealing with pig trains, the expected pig
speed and separation should be used to configure a suitable value for the OUTPUT DELAY such
that the unit will not detect the same pig twice but will enter LISTENING MODE in time to
detect the next pig.
Once the OUTPUT DELAY has expired, or the control button is pressed the unit will
automatically return to LISTENING MODE.
3.5. RELAY OUTPUT
Refer to section 5 EXTERNAL CONNECTIONS for connection instructions.
While in LISTENING state, the Normally Closed (NC) contact of the relay will be connected to
the Common contact (COM) and the Normally Open (NO) contact will be open.
While in DETECTION state, the Normally Closed contact will be open and the Normally Open
contact will be connected to the Common contact.
Note that the relay logic may be INVERTED as per see section 3.7.7 SET OUTPUT.

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3.6. CURRENT LOOP OUTPUT
Refer to section 5 EXTERNAL CONNECTIONS for connection instructions.
While in LISTENING state the loop current shall be 5mA ±1mA.
While in DETECTION state the loop current shall be 19mA ±1mA.
Note that if the MODBUS INTERFACE is fitted then inverting the relay logic as per section 3.7.7
SET OUTPUT will also reverse the state of the CURRENT LOOP output. See section 5.3 MODBUS
PCB OPTION for more information.
3.7. SINGLE BUTTON MENU INTERFACE
While in LISTENING MODE, 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.
While in the menu system, every time the user presses the control button the CURSOR will
move down one line and the COUNTDOWN INDICATOR will be reset to 5. Once the CURSOR is
pointing at the desired item the user simply allows the COUNTDOWN INDICATOR 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 COUNTDOWN INDICATOR to reach 0.
If you do not wish to modify a parameter then simply allow the COUNTDOWN INDICATOR to
reach 0 without operating the control button. The menu system is designed so that the unit
will always return to LISTENING MODE if the control button is left released for a long enough
time.

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3.7.1. EXIT
The first item on every page of the menu system is EXIT. If no other selection is made then
EXIT is selected by default and the unit will exit the menu system and return to LISTENING
MODE.
3.7.2. STATUS
The STATUS screen is also shown as part of section 3.2 TURN ON SEQUENCE. It shows the
Date, Time, Output Delay, Relay State and the Number of Logged Events. The STATUS screen
can be halted by pressing and holding the control button.
3.7.3. VIEW EVENTS
When VIEW EVENTS is selected, the unit automatically scrolls
through logged event data. If no data has been logged, then a
NO EVENTS message will be displayed. If logged data is
available, then screens similar to those shown will be displayed.
Each screen displays the event number along with the time and
date of the event. The current time and date is displayed at the
top of the screen. If the countdown indicator is allowed to reach
zero, then the next event screen will appear until all events
have been displayed, after which the unit will return to
LISTENING MODE. If the control button is pressed at any point
then the unit will immediately return to LISTENING MODE.
3.7.4. DELETE ALL EVENTS
When DELETE ALL EVENTS is selected, a screen showing the message “*WARNING* PRESS TO
ERASE ALL EVENTS” will appear. If the user wishes to delete all logged data, then they should
press the control button once before the countdown indicator reaches zero. If you do not wish
to erase all logged data, then simply allow the countdown indicator to reach zero without
pressing the control button.
3.7.5. SHUTDOWN
Selecting this item will switch the unit off. When the countdown indicator reaches zero, the
display will go blank and the LEDs will flash once. The unit is fitted with a non-volatile memory
which will remember all settings (such as OUTPUT DELAY and TIME/DATE) until the next time
the unit is switched on. It is imperative that the unit is turned off using this command rather
than simply disconnecting the battery to allow any memory storage processes to terminate
prior to turning OFF.
3.7.6. MORE…
Selecting this item shows the next page of the menu system. See the figure in section 3.7
SINGLE BUTTON MENU INTERFACE for all available pages.