Online 3015X ALKALINE Series User manual

ONLINE ELECTRONICS LTD
3015_5001_A01 Page 1 of 17
Online Electronics Ltd
Online House
Blackburn Business Park
Woodburn Road, Blackburn
Aberdeen
AB21 0PS
UK
[phone]
www.online-electronics.com
[email protected]
3015X ALKALINE SERIES
ELECTROMAGNETIC TRANSMITTER
OPERATING MANUAL
The 3015X transmitter is an electromagnetic transmitter that
can be used for pig tracking and locating functions, intended
for use in pipeline diameters of 8” to 12”

ONLINE ELECTRONICS LTD
3015_5001_A01 Page 2 of 17
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:

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3015_5001
Checked
(IF APPLICABLE)
Date
(IF APPLICABLE)
Approved
Date
Rev
Date
By
Summary of change
A00
03/08/17
BG
CR00485: Was 3015X ATEX ALKALINE EM TRANSMITTER MANUAL
RevB02. CR00380: Address change. CR00499: Front cover update.
A01
09/10/17
BG
CR0049: Cover page update
COMMENTS:
ca , 09:06:32, 11/10/2017

ONLINE ELECTRONICS LTD
3015_5001_A01 Page 4 of 17
CONTENTS Page
1. GENERAL DESCRIPTION ......................................................................................... 5
2. SPECIFICATIONS ................................................................................................... 6
3. RULES FOR SAFE OPERATION ................................................................................. 7
4. OPERATION .......................................................................................................... 8
4.1. TURNING ON..................................................................................................... 8
4.2. TURNING OFF ................................................................................................... 8
4.3. FUNCTION TEST ................................................................................................ 9
4.4. DEPLOYMENT .................................................................................................... 9
4.5. MODE SELECT ................................................................................................. 10
4.6. INSTALLATION ................................................................................................ 11
4.7. BATTERY LIFETIME .......................................................................................... 12
4.8. BATTERY REPLACEMENT ................................................................................... 13
5. MAINTENANCE .................................................................................................... 14
5.1. O-RING REPLACEMENT..................................................................................... 14
5.2. ROUTINE MAINTENANCE AND STORAGE............................................................. 15
6. DISPOSAL OF UNIT.............................................................................................. 16
7. WARRANTY ......................................................................................................... 16
8. APPENDIX A –ATEX SPECIFIC INSTRUCTIONS ........................................................ 17

ONLINE ELECTRONICS LTD
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1. GENERAL DESCRIPTION
The 3015X Electromagnetic transmitter is an ATEX certified EM transmitter 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.
It is possible to detect the EM transmissions from a 3015X transmitter through pipeline walls in
excess of 40mm thick, however performance is dependent on several factors including the type
of receiver and antenna used, distance between antenna and transmitter, pig design, pig
speed, pipeline diameter, pipeline material and background EM noise levels. Please contact
OEL to discuss the most effective configuration.
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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2. SPECIFICATIONS
NOTE THAT THE SPECIFICATIONS BELOW ARE VALID FOR THE STANDARD
CONFIGURATION ONLY. REFER TO PAGE 2 OF THIS MANUAL FOR THE
CONFIGURATION INFORMATION SPECIFIC TO THE TRANSMITTER BEING USED.
GENERAL:
Lifetime in continuous mode at +20°C in air ............................................................. 5 days
Lifetime pulsing 0.4sec ON / 0.6sec OFF at +20°C in air............................................. 9 days
Lifetime pulsing 0.4sec ON / 1.6sec OFF at +20°C in air............................................ 17 days
Lifetime pulsing 0.4sec ON / 2.6sec OFF at +20°C in air........................................... 25 days
Lifetime pulsing 0.4sec ON / 3.6sec OFF at +20°C in air........................................... 31 days
Lifetime pulsing 0.4sec ON / 4.6sec OFF at +20°C in air........................................... 37 days
Alkaline batteries................................ 5x DURACELL INDUSTRIAL ID1300 ALKALINE D CELLS
Standard signal at 1m with OEL reference antenna at +20°C in air ...........................624mVpp
Standard frequency ............................................................................................... 21.8Hz
Operating temperature range......................................................................... -20 to +54°C
External pressure rating ......................................................................................... 500bar
Bump rating.............................................................................................................. 20G
Weight in air (including batteries)................................................................................. 7kg
MATERIALS:
Housing material .................................................. ASTM B348 GRADE 5 TITANIUM Ti-6Al-4V
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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3. RULES FOR SAFE OPERATION
⚠WARNING: The Special Conditions for Safe Use as detailed in Section 8 APPENDIX A –
ATEX SPECIFIC INSTRUCTIONS must be followed at all times.
⚠WARNING: Any operation involving pressure is potentially hazardous. No person should
use this equipment unless fully aware of the potential hazards of working with pressurised
vessels. The purchaser of this equipment is responsible for the training and competence of
operators and the manner in which it is used. This manual should be read through and
understood before installation and commissioning so that the operator is familiar with the
equipment. Contact Online Electronics Ltd immediately should any difficulty arise in the use of
this equipment.
⚠WARNING: DO NOT open when an explosive atmosphere may be present. Always use
caution when opening equipment which has been in a pressurised environment. It is possible
for pressure to leak into the equipment and remain there even after external pressure has
been removed. ALWAYS point the end to be opened towards a safe area and away from
yourself or others. Contact Online Electronic immediately if there is a suspicion that the
equipment has become pressurised.
⚠WARNING: Only DURACELL INDUSTRIAL ID1300 ALKALINE cells are permitted to be used
in this equipment.
⚠WARNING: Replace all batteries at the same time. NEVER install used batteries. NEVER
install a mix of new and used batteries. USE ONLY new batteries from the same package or
manufacturing batch. DO NOT mix different brands or types of batteries. ALWAYS observe
correct battery polarity. New batteries should be installed before each deployment.
⚠WARNING: Do not expose to aggressive solvents or chemicals which could be harmful to
the HOUSING, O-RINGS, CONNECTORS or any other parts of the equipment.
⚠CAUTION: Opening of the equipment should take place in a clean laboratory environment.
⚠CAUTION: 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.
⚠CAUTION: It is possible for liquids to become trapped in threads and/or gaps around
openings. ALWAYS point the end to be opened downwards to allow any trapped liquid to drain
out of and not into the equipment.
⚠CAUTION: If the transmitter is to be placed in storage, always ensure that it is turned OFF
and the batteries are removed and stored separately.

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4. OPERATION
Familiarise yourself with all of the rules for the safe operation of this equipment as described in
Section 3 RULES FOR SAFE OPERATION.
4.1. TURNING ON
1. 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.
2. Use an EM receiver system to confirm that the transmitter is functioning properly at the
expected pulse rate.
4.2. TURNING OFF
1. 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.
2. Use an EM receiver system to confirm that the transmitter has turned off.

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4.3. FUNCTION TEST
An OEL EM receiver system is required to receive the signal from a 3015X 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 10m away and parallel to the transmitter.
2. Activate the transmitter as detailed in Section 4.1 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 4.5 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 4.2 TURNING OFF.
7. If all results were as expected then the system is functional.
4.4. DEPLOYMENT
Before each deployment ensure that the following checks have been completed.
1. Ensure that the transmitter has been installed as detailed in Section 4.6 INSTALLATION.
2. Visually inspect all system components to ensure that they are secure and undamaged.
3. Refer to the Page 2 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 4.1 TURNING ON.
5. Complete a 4.3 FUNCTION TEST.

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4.5. MODE SELECT
1. Familiarise yourself with all of the warnings given at the start of Section 3 RULES FOR
SAFE 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) or RATE 2 (switch in lower position or CONT). Refer to
the cover of this manual for the rates available for 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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4.6. INSTALLATION
⚠WARNING: The Special Conditions for Safe Use as detailed in Section 8 APPENDIX A –
ATEX SPECIFIC INSTRUCTIONS must be followed at all times.
⚠WARNING: 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.
⚠CAUTION: 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.
⚠CAUTION: 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. 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
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.

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4.7. 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 4.6 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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4.8. BATTERY REPLACEMENT
1. Familiarise yourself with all warnings given at the start of Section 3 RULES FOR SAFE
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 DURACELL INDUSTRIAL ID1300 Alkaline D cells and battery discs. 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. Place the
battery discs safely to the side so they don’t get lost.
6. Observing the battery polarity shown in the figure below, insert 5x new DURACELL
INDUSTRIAL ID1300 Alkaline D cells into the battery compartment POSITIVE END first with
a 3015X-029 ALK BATTERY DISC between neighbouring cells. A total of 4x battery discs
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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5. MAINTENANCE
Familiarise yourself with all of the rules for the safe operation of this equipment as described in
Section 3 RULES FOR SAFE OPERATION.
5.1. O-RING REPLACEMENT
1. Familiarise yourself with all of the warnings given at the start of Section 5 MAINTENANCE.
2. Using a 10mm AF Allen key fully remove the bleed screw.
3. Using a 2.5mm AF Allen key fully unscrew the M5 locking grub screw on the PCB and
BATTERY ENDCAPS. The grub screws may be screwed back in 3 turns to prevent them
getting lost.
4. Using the supplied ENDCAP REMOVAL TOOL, fully remove the BATTERY ENDCAP, any
batteries and battery discs, then the PCB ENDCAP.
5. Referring to the figure below, remove all O-rings and clean all sealing surfaces on all parts.
6. Examine all surfaces for signs of corrosion, scoring, and other damage. If there is
excessive damage the mechanical parts may need to be replaced.
7. Lightly grease all sealing surfaces using a suitable grease (e.g. DOW CORNING MOLYKOTE
111 COMPOUND).
8. Lightly grease each O-ring with a suitable grease (e.g. DOW CORNING MOLYKOTE 111
COMPOUND) before fitting.
9. Referring to Section 4.8 BATTERY REPLACEMENT re-insert the batteries and battery discs,
then refit the BATTERY ENDCAP to the BATTERY end of the housing and the PCB ENDCAP
to the PCB end of the housing using the ENDCAP REMOVAL TOOL. Do not use a vice or
spanner, the endcaps only need to be hand tight.
10. Tighten the M5 grub screw on each ENDCAP (until the grub screw engages with the
housing to lock each endcap in place). Note that very little torque is required. Damage
may occur if over tightened.
11. Examine the bleedscrew spring pin for any signs of damage, ensure it is not stuck and has
a smooth travel of approximately 3mm. Fully tighten the bleed screw then 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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5.2. ROUTINE MAINTENANCE AND STORAGE
All Online Electronics Ltd transmitters are designed to require minimum maintenance. The
housing should be cleaned using fresh water and cleaning agents as necessary (e.g. WD40).
Do not use chemicals which could be damaging to the housing or O-rings.
Check flame paths / threads on the housing body and endcaps for signs of corrosion or
damage. If badly pitted or damaged, replace the relevant component.
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.
Online Electronics Ltd can supply redress kits containing a complete set of replacement
batteries, O-rings, O-ring grease, battery discs and endcap locking screws, contact Online
Electronics Ltd for more information.
If the transmitter is to be placed in storage for a long period of time, remove the batteries and
battery discs from the transmitter and store separately.
As a minimum the bleed screw must be loosened 3 full turns to switch the transmitter off.
A
The Transmitter is shipped with a nylon washer underneath the bleed screw to prevent the unit
being accidentally switched on in transit. This washer must be removed before the transmitter
can be turned on.

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6. DISPOSAL OF UNIT
Online Electronics Ltd (OEL) takes its responsibilities under the WEEE Regulations extremely
seriously and has taken steps to be compliant in line with our corporate and social
responsibilities. In the UK, OEL has joined a registered compliance scheme WeeeCare
(registration number WEE/MP3538PZ/SCH).
Electrical and electronic equipment should never be disposed of with general waste but must
be separately collected for the proper treatment and recovery.
The crossed out bin symbol, placed on the product, reminds you of the need to dispose of it
correctly at the end of its life.
When buying a new product you will have the possibility to return, free of charge, another end
of life product of equivalent type that has fulfilled the same functions as the supplied
equipment. These items may be deposited at:
Online Electronics Ltd
Online House
Blackburn Business Park
Woodburn Road
Aberdeen
AB21 0PS
UK
Alternatively, to arrange a collection of any waste electrical equipment, obligated to OEL please
telephone WeeeCare on 0844 800 2004.
7. WARRANTY
Online products are guaranteed for one year from the date of purchase. Goods should be
returned transportation prepaid to Online Electronics Limited.
There is no charge for parts or labour should any product require repair due to a
manufacturing deficiency during the guarantee period.
In the event of a manufacturing deficiency the inward transportation costs will be repaid to the
client.

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8. APPENDIX A –ATEX SPECIFIC INSTRUCTIONS
EQUIPMENT: 3015X EM transmitters
MANUFACTURER: Online Electronics Ltd
Online House
Blackburn Business Park
Woodburn Road
Blackburn
Aberdeen
AB21 0PS
UK
Tel: [phone]
Web: www.online-electronics.com
NOTIFIED BODY NUMBER: 0891
ATEX CERTIFICATE: TRAC 09 ATEX 21218X
MARKINGS: II 2 G Ex d IIB T4..T6X
APPLICABLE STANDARDS: EN 60079-0:2012+A11:2013
EN 60079-1:2014
SPECIAL CONDITIONS FOR SAFE USE:
1. The temperature class is reliant on the operating ambient temperature as follows:
Ambient temperature
T Class
-20°C to +40°C
T6
-20°C to +80°C
T4
2. Warning –Do not open when an explosive atmosphere may be present.
3. Use only ALKALINE, 1.5V, 18Ah, D cells, rated for at least 250mA continuous current
(DURACELL INDUSTRIAL ID1300 recommended).
4. Enclosures manufactured from titanium must be installed such that ignition sources due to
impact and friction sparks are excluded.