Online electronics 3014x atex User manual

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 1 of 16

OPERATING MANUAL

CONFIGURATION INFORMATION

SERIAL NUMBER:

OUTPUT SIGNAL:

REPETITION RATE 1:

RATE 1 BATTERY LIFE AT +20°C:

REPETITION RATE 2:

RATE 2 BATTERY LIFE AT +20°C:

3014X ATEX

EM TRANSMITTER

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 3 of 16

CONTENTS Page

1. GENERAL DESCRIPTION ......................................................................................... 4

2. SPECIFICATIONS ................................................................................................... 5

3. OPERATION .......................................................................................................... 6

3.1. TURNING ON..................................................................................................... 6

3.2. TURNING OFF ................................................................................................... 6

3.3. FUNCTION TEST ................................................................................................ 7

3.4. DEPLOYMENT .................................................................................................... 7

3.5. MODE SELECT ................................................................................................... 8

3.6. INSTALLATION .................................................................................................. 9

3.7. BATTERY LIFETIME .......................................................................................... 10

3.8. BATTERY REPLACEMENT ................................................................................... 11

3.9. LITHIUM BATTERY SAFETY................................................................................ 12

4. MAINTENANCE .................................................................................................... 13

4.1. O-RING REPLACEMENT..................................................................................... 13

4.2. ROUTINE MAINTENANCE AND STORAGE ............................................................. 14

5. DISPOSAL OF UNIT.............................................................................................. 15

6. WARRANTY ......................................................................................................... 15

7. APPENDIX A –ATEX SPECIFIC INSTRUCTIONS ........................................................ 16

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 4 of 16

1. GENERAL DESCRIPTION

The 3014X Electromagnetic transmitter is an ATEX certified EM transmitter that can be used

for pig tracking and location functions. The transmitter operates effectively in buried pipelines,

pipelines carrying gas and in pipeline bundles where acoustic transmitters are either less

effective or ineffective.

The transmitter emits a 21.8Hz signal and an inherent EM null spot is detectable when the EM

receiver antenna is at 90 degrees to and pointing at the centre of the transmitter allowing

centimetre accurate positioning of a pig.

The transmitter can be changed between two pulsing transmission rates via an easily

accessible slide switch inside the transmitter.

The transmitter is configured for use with Lithium batteries only. Lithium batteries provide a

significant improvement in battery lifetime and operation particularly at temperature extremes.

A non-ATEX version of the transmitter can be manufactured with specially designed endcaps

which allow fitting of pigging discs directly to the transmitter - the transmitter itself becomes

the pig body. This dramatically increases the received EM signal because it no longer needs to

propagate through an additional pig body as well as the pipeline.

Parameters such as lifetime, pulse rate, frequency, and output level can be customised during

manufacture, please contact Online Electronics Ltd for more details.

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 5 of 16

2. SPECIFICATIONS

NOTE THAT THE SPECIFICATIONS BELOW ARE VALID FOR THE STANDARD

CONFIGURATION ONLY. REFER TO THE COVER OF THIS MANUAL FOR THE

CONFIGURATION INFORMATION SPECIFIC TO THE TRANSMITTER BEING USED.

GENERAL:

Lifetime in continuous mode at +20°C in air .......................................................... 6.5 days

Lifetime pulsing 0.4sec ON / 0.6sec OFF at +20°C in air........................................... 14 days

Lifetime pulsing 0.4sec ON / 1.6sec OFF at +20°C in air............................................ 25 days

Lifetime pulsing 0.4sec ON / 2.6sec OFF at +20°C in air........................................... 36 days

Lifetime pulsing 0.4sec ON / 3.6sec OFF at +20°C in air........................................... 46 days

Lifetime pulsing 0.4sec ON / 4.6sec OFF at +20°C in air........................................... 54 days

Lithium batteries ..............................2x ELECTROCHEM 3B0035-TC PRIMARY LITHIUM D CELL

Standard signal at 1m with OEL reference antenna at +20°C in air ...........................185mVpp

Standard frequency ............................................................................................... 21.8Hz

Operating temperature range......................................................................... -40 to +80°C

External pressure rating ......................................................................................... 225bar

Bump rating.............................................................................................................. 20G

Typical weight including batteries .............................................................................. 3.5kg

MATERIALS:

Housing material ..............................................................316 STAINLESS STEEL EN 1.4401

Endcap material ................................................................ALLOY BRONZE CA104 EN 12163

Bleedscrew material..........................................................316 STAINLESS STEEL EN 1.4401

O-rings ............................................................... NBR70 (standard) / FKM936 (heavy duty)

ATEX:

Notified body number................................................................................................ 0891

Type examination number ............................................................... TRAC 09 ATEX 21218 X

Code......................................................................................... Ex II 2 G Ex d IIB T4..T6X

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 6 of 16

3. OPERATION

THE SPECIAL CONDITIONS FOR SAFE USE DETAILED IN SECTION 7 APPENDIX A –

ATEX SPECIFIC INSTRUCTIONS OF THIS MANUAL MUST BE OBSERVED AND

FOLLOWED AT ALL TIMES

WARNING 1 –THE TRANSMITTER SHOULD ONLY BE OPENED IN A CLEAN, DRY,

LABORATORY ENVIRONMENT.

WARNING 2 –TO PREVENT THE FORMATION OF CONDENSATION WITHIN THE

TRANSMITTER ALLOW THE TRANSMITTER TEMPERATURE TO STABILISE WITHIN THE

LABORATORY ENVIRONMENT FOR A MINIMUM OF 6 HOURS PRIOR TO OPENING.

WARNING 3 –IF THE TRANSMITTER IS BEING OPENED FOR THE FIRST TIME AFTER

IMMERSION IN PIPELINE PRODUCTS THEN EXPECT SOME LIQUID TO BE PRESENT

WITHIN THE ENDCAP THREADS. CARE SHOULD BE TAKEN WHEN OPENING THE UNIT

TO ALLOW ANY LIQUID TO DRAIN OUT OF AND NOT IN TO THE TRANSMITTER.

WARNING 4 –REPLACE ALL BATTERIES AT THE SAME TIME. NEVER USE A MIX OF

NEW AND USED BATTERIES. NEVER USE A MIX OF BATTERIES FROM DIFFERENT

BATCHES. USE ONLY ELECTROCHEM 3B0035-TC LITHIUM D CELLS. ALWAYS OBSERVE

CORRECT BATTERY POLARITY AND USE OF THE BATTERY DISC. REFER TO SECTION

3.9 LITHIUM BATTERY SAFETY FOR FURTHER INFORMATION.

WARNING 5 –IF THE TRANSMITTER IS TO BE PLACED IN STORAGE ALWAYS ENSURE

THAT IT IS TURNED OFF AND THE BATTERIES REMOVED AND STORED SEPARATELY.

3.1. TURNING ON

1. Familiarise yourself with all warnings given at the start of Section 3 OPERATION.

2. To turn the transmitter on, fully tighten the bleed screw using a 10mm AF Allen key. Do

not use excessive torque. The transmitter takes approximately 5 seconds to turn on. Note

that the transmitter is usually shipped with a Nylon washer under the bleed screw to

prevent accidental activation during transport. This must be removed before the

transmitter can be turned on.

3. Use an EM receiver system to confirm that the transmitter is functioning properly at the

expected pulse rate.

3.2. TURNING OFF

1. Familiarise yourself with all warnings given at the start of Section 3 OPERATION.

2. To turn the transmitter off, loosen the bleed screw 3 full turns using a 10mm AF Allen key.

To prevent the bleed screw being lost, or the transmitter accidentally being turned back

on, the bleed screw should be held in this position with some tape.

3. Use an EM receiver system to confirm that the transmitter has turned off.

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 7 of 16

3.3. FUNCTION TEST

An OEL EM receiver system is required to receive the signal from a 3014X transmitter. Refer to

the relevant EM receiver manual for instruction on setup and operation of the EM receiver

system.

1. Place the EM receiver antenna approximately 5m away and parallel to the transmitter.

2. Activate the transmitter as detailed in Section 3.1 TURNING ON.

3. Confirm that a clear signal is received.

4. Switch the transmitter between OFF, RATE 1 and RATE 2 several times to ensure that the

signal received reacts as expected. Refer to Section 3.5 MODE SELECT for further

information on changing transmission rates.

5. An inherent null spot is detectable when the antenna is at 90 degrees to and pointing at

the centre of the transmitter allowing accurate positioning of a pig. Refer to the relevant

EM receiver manual for further information.

6. Turn OFF the transmitter as detailed in Section 3.2 TURNING OFF.

7. If all results were as expected then the system is functional.

3.4. DEPLOYMENT

Before each deployment ensure that the following checks have been completed.

1. Ensure the transmitter has been installed as detailed in Section 3.6 INSTALLATION.

2. Visually inspect all system components to ensure that they are secure and undamaged.

3. Refer to the front cover of this manual for the expected battery lifetime and ensure that it

is adequate for the planned operations.

4. Activate the transmitter as detailed in Section 3.1 TURNING ON.

5. Complete a 3.3 FUNCTION TEST.

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 8 of 16

3.5. MODE SELECT

1. Familiarise yourself with all warnings given at the start of Section 3 OPERATION.

2. If not already loosened, using a 10mm AF Allen key, loosen the bleed screw 3 full turns to

release any internal pressure and to turn the transmitter off. There is no need to fully

remove the bleed screw. If you do so it may be lost.

3. Using a 2.5mm AF Allen key fully unscrew the M5 locking grub screw on the PCB ENDCAP.

The grub screw may be screwed back in 3 turns to prevent it getting lost.

4. Using the supplied ENDCAP REMOVAL TOOL, fully remove the PCB ENDCAP to reveal the

PCB assembly and switch as shown in the figure below.

5. Set the MODE SWITCH to the desired position. The switch can be set to either RATE 1

(switch in upper position or PULS on older units) or RATE 2 (switch in lower position or

CONT on older units). Refer to the cover of this manual for the rates available from the

transmitter being used.

6. Examine the O-ring seals for any signs of contamination or damage, replace and/or re-

grease if necessary.

7. Replace the PCB ENDCAP using the supplied ENDCAP REMOVAL TOOL. Do not use a vice or

spanner, it only needs to be hand tight. Damage may occur if over tightened.

8. Tighten the M5 grub screw (until the grub screw engages with the housing to lock the PCB

ENDCAP). Note that very little torque is required. Damage may occur if over tightened.

9. Fully tighten the bleed screw to turn on the transmitter. Use an EM receiver system to

confirm transmitter function and correct transmission rate.

10. If the transmitter is not to be used immediately after the mode has been selected, loosen

the bleed screw 3 full turns to switch the transmitter off and use some tape to hold the

bleed screw in this position to prevent it being lost or the transmitter being accidentally

turned back on.

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 9 of 16

3.6. INSTALLATION

1. All EM transmitters will induce electrical currents in any conductive materials closely

surrounding them which can result in a severe reduction in signal strength and/or battery

lifetime. This effect can be minimised by reducing the amount of conducting material

surrounding the transmitter. Leave as much of the transmitter exposed as possible. Any

slits or apertures which can be made in the surrounding material will help. Use materials

with as high resistance as possible. Non-conducting materials such as plastics will not

suffer from this effect. EM transmitters must not be surrounded by low resistance metals

such as aluminium (including tubes or mounting clamps) under any circumstances.

2. Any magnetic material surrounding the transmitter will tend to block the EM signal from

the transmitter and reduce the received signal strength outside the pipeline. This effect can

be minimised by reducing the amount of magnetic material surrounding the transmitter.

Leave as much of the transmitter exposed as possible. Any slits or apertures which can be

made in the surrounding material will help. Use materials with as low magnetic

permeability as possible. Non-magnetic materials such as plastics will not suffer from this

effect.

3. The transmitter must be mounted in such a way that no movement or vibration

whatsoever is possible (e.g. clamped). If the transmitter is allowed to rattle and/or vibrate

within the pig then the resultant hammering effect can exceed the bump rating of the

transmitter leading to damage and/or failure. This is particularly important in gas pipelines.

For optimum performance the transmitter should be clamped inside a plastic pig body or

plastic guide discs should be clamped around the transmitter to form a pig. The advantage of

these methods is the fact that there is no metal around the transmitter apart from the pipeline

itself. Two alternative mounting arrangements are shown below. The first uses several lengths

of threaded studding to clamp the transmitter between two plates. The second uses a clamping

disc. The advantage of these arrangements is that they have limited amounts of metal around

the transmitter and will therefore have limited effect on the transmitter performance. Please

contact Online Electronics for further information and guidelines regarding EM transmitter

mounting and installation.

The table below shows the typical characteristics of several potential pig and mounting

materials with the best choice at the top, and the worst choice at the bottom. 316 stainless

steel provides a good balance of properties and cost. An aluminium alloy would be a very poor

choice because of the very low resistivity and should not be used under any circumstances.

MATERIAL

RESISTIVITY (µΩ.m)

MAGNETIC PERMEABILITY

PLASTIC

∞

1.000

316 STAINLESS STEEL

0.75

1.008

2205 DUPLEX SS

0.80

>25.0

1005 STEEL

0.20

>100

ALUMINIUM ALLOYS

0.04

1.000

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 10 of 16

3.7. BATTERY LIFETIME

The operating temperature which the transmitter is used at alters the operating lifetime.

Typically colder temperatures will shorten the stated lifetime as shown by the figure below.

Note that upon customer request, the transmitters can be adjusted at Online Electronics Ltd to

provide a stronger signal at the expense of lifetime or extended lifetime at the expense of

signal, contact Online Electronics Ltd for more details and to discuss your requirements.

In extreme circumstances the transmitter operating lifetime may be reduced by how the

transmitter is installed on a pig. For example, if it is installed inside an aluminium tube, the

operating lifetime may be reduced to as little as 50%. Refer to Section 3.6 INSTALLATION

within this manual for tips on how to achieve optimum performance from the transmitter with

regards to the mounting arrangement.

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 11 of 16

3.8. BATTERY REPLACEMENT

1. Familiarise yourself with all of the warnings given at the start of Section 3 OPERATION.

2. Using a 10mm AF Allen key loosen the bleed screw 3 full turns to release any internal

pressure and to turn the transmitter off. There is no need to fully remove the bleed screw.

If you do so it may be lost.

3. Using a 2.5mm AF Allen key fully unscrew the M5 locking grub screw on the BATTERY

ENDCAP. The grub screw may be screwed back in 3 turns to prevent it getting lost.

4. Using the supplied ENDCAP REMOVAL TOOL, fully remove the BATTERY ENDCAP.

5. Remove all ELECTROCHEM 3B0035-TC Lithium cells and the battery disc. Visually inspect

the batteries, contact Online Electronics Ltd immediately if there are any signs of damage

or electrolyte leakage. Dispose of the old batteries in a responsible way. Refer to section

3.9 LITHIUM BATTERY SAFETY for further guidance. Place the battery disc safely to one

side so it doesn’t get lost.

6. Observing the battery polarity shown in the figure below, insert 2x new ELECTROCHEM

3B0035-TC Lithium D cells into the battery compartment POSITIVE END first with a 3015X-

031 LIT BATTERY DISC between neighbouring cells. A total of 1x battery disc will be

required.

7. Once all batteries are installed ensure that it is the FLAT, NEGATIVE END of the batteries

which you see when looking into the open end of the transmitter.

8. Examine the O-ring seals for any signs of contamination or damage, replace and/or re-

grease if necessary.

9. Replace the BATTERY ENDCAP using the supplied ENDCAP REMOVAL TOOL. Do not use a

vice or spanner, it only needs to be hand tight. Damage may occur if over tightened.

10. Tighten the M5 grub screw (until the grub screw engages with the housing to lock the

BATTERY ENDCAP). Note that very little torque is required. Damage may occur if over

tightened.

11. Fully tighten the bleed screw to turn on the transmitter. Using an EM receiver, confirm

transmitter function and correct transmission rate.

12. If the transmitter is not to be used immediately after battery replacement, loosen the

bleed screw 3 full turns to switch the transmitter off and use some tape to hold the bleed

screw in this position to prevent it being lost or the transmitter being accidentally turned

back on.

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 12 of 16

3.9. LITHIUM BATTERY SAFETY

The information given in this section is for reference only. It should not be used in

place of appropriate local regulations or other legal requirements. Online Electronics

Ltd are not responsible for any incident that occurs due to misuse or abuse of their

products or misuse or abuse of lithium cells used by their products.

The batteries used in this transmitter have a very high energy density giving the transmitter a

superior lifetime. However, the same properties which result in a high energy density also

contribute to potential hazards if the energy is released at a fast, uncontrolled rate. With

proper use and handling, ELECTROCHEM cells have demonstrated an excellent safety record in

applications where safety and reliability is of utmost importance.

Because of the recognition of hazards associated with high energy density systems, safety has

been incorporated into the design and manufacture of ELECTROCHEM cells and the Online

Electronics Ltd transmitter. While the transmitter and cells have been designed to be tolerant

to adverse conditions, there are limitations. In particular, the transmitter and cells must be

protected from excessive heat and excessive mechanical abuse. The cells have warnings

printed on their label that cautions against the following conditions:

Short circuit

Charge

Forced over discharge

Excessive heating or incineration

Crush, puncture or disassembly

Rough handling or excessive shock and vibration

Not guarding against these conditions may result in a hot cell that could either vent or explode

at the instant of abuse, or, more typically, the cell shall heat up over a period of time and

subsequently vent or explode when its critical temperature is reached. Problems associated

with hazardous conditions can be greatly reduced by observing the following guidelines:

When handling the transmitter:

Never drop the transmitter. This may damage the cells inside. If dropped, the

cells should be replaced. During operation observe the shock and vibration limits given.

Never store or operate the transmitter outside its operating temperature range.

Always replace all batteries at the same time. Replace with NEW batteries from

the SAME batch. This will help to prevent over discharge of individual cells.

Always observe correct battery polarity when replacing batteries.

When handling loose cells:

Cover all metal work surfaces with an insulating material

The work area should be clean and free of sharp objects that could puncture the

insulating sleeve on each cell

Personnel handling cells should remove all jewellery that could come into contact

with battery terminals

Never stack or scatter loose cells. They should be placed in insulating carrying

trays with individual compartments for each cell.

Cells should be inspected for physical damage, possibly caused by dropping.

Cells with dented cases or terminal caps should be disposed of in a responsible manner.

Measure the Open Circuit Voltage (OCV) of cells. The nominal OCV is 3.9V. An

open circuit voltage of 0.0V is indicative of a blown internal fuse.

The cells must never be disassembled.

REFERENCE: http://www.electrochemsolutions.com/pdf/Safety_and_Handling_Guide.pdf

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3014X ATEX EM TRANSMITTER MANUAL RevB00 Page 13 of 16

4. MAINTENANCE

THE SPECIAL CONDITIONS FOR SAFE USE DETAILED IN SECTION 7 APPENDIX A –

ATEX SPECIFIC INSTRUCTIONS OF THIS MANUAL MUST BE OBSERVED AND

FOLLOWED AT ALL TIMES.