Weir MPM User manual

The Weir Group PLC
Weir Mechatronics
1 Marden St
Artarmon, NSW
2064, Australia
Tel: [phone]
Weir Industrial Gateway
Setup guide
Document ID: 00-40-20-40_20
Revision: 0.5
November 15, 2017
Copyright © Weir Minerals Australia Ltd 2017.
Commercial in Confidence. All rights reserved

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page i
Document Approval
Name
Designation
Date
Signature
Submitted By
C.Strudwicke
Principle Control
Systems Engineer
Accepted By
C.Strudwicke
Principle Control
Systems Engineer
Approved By
B.Baker
Head of
Mechatronics

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page ii
Document History
Revision
Date
Author
Details
0.1
9-3-2017
C.Strudwicke
First version
0.2
21-03-2017
C.Strudwicke
Addition of feedback relating to certification
requirements
0.3
08-09-2017
W. Cooke
Addition of feedback relating to certification
requirements
0.4
10-06-2017
W. Cooke
Addition of feedback relating to certification
requirements
0.5
11-15-2017
W. Cooke
Document name change to match regulatory
documents

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page iii
Table of Contents
DOCUMENT APPROVAL ..................................................................................................................................I
DOCUMENT HISTORY ....................................................................................................................................II
1INTRODUCTION AND SAFETY.................................................................................................................1
1.1 INTRODUCTION .......................................................................................................................................... 1
1.2 SCOPE ...................................................................................................................................................... 1
1.3 TARGET AUDIENCE...................................................................................................................................... 1
1.4 SAFETY ..................................................................................................................................................... 1
1.4.1 Safety Terminology and Symbols ...................................................................................................... 1
1.4.2 User Safety ........................................................................................................................................ 1
1.4.3 Warnings........................................................................................................................................... 2
1.4.4 Determination That Equipment Can be Used Safely in the Intended Area........................................ 3
2TRANSPORTATION AND STORAGE .........................................................................................................4
2.1 CONSIGNMENT RECEIPT AND UNPACKING ........................................................................................................ 4
2.2 TRANSPORTATION GUIDELINES...................................................................................................................... 4
2.3 STORAGE .................................................................................................................................................. 4
3SYSTEM COMPONENTS .........................................................................................................................4
4SYSTEM ARCHITECTURE.........................................................................................................................6
5PSM –POWER SUPPLY MODULE............................................................................................................7
5.1 PARAMETERS RELEVANT TO INSTALLATION AND OPERATION ................................................................................ 7
5.2 INSTALLATION ............................................................................................................................................ 8
6MPM –MAIN PROCESSING MODULE .....................................................................................................9
6.1 PARAMETERS RELEVANT TO INSTALLATION AND OPERATION ................................................................................ 9
6.2 IMAGES .................................................................................................................................................... 9
6.3 CONNECTOR KEYING TYPES ........................................................................................................................ 12
6.4 LED INDICATORS ...................................................................................................................................... 12
6.5 INSTALLATION .......................................................................................................................................... 13
Mounting plate & Hardware ............................................................................................................... 13
6.5.1.............................................................................................................................................................. 13
6.5.2 MPM & PSM.................................................................................................................................... 14
6.5.3 Hazardous Location Requirements.................................................................................................. 16
6.5.4 Antenna........................................................................................................................................... 17
7RSP –REMOTE SIGNAL PROCESSOR .....................................................................................................22
7.1 PARAMETERS RELEVANT TO INSTALLATION AND OPERATION .................................................................. 22
7.2 IMAGES ................................................................................................................................................. 22
7.3 CONNECTOR KEYING TYPES ........................................................................................................................ 24
7.4 LED INDICATORS ...................................................................................................................................... 25
7.5 INSTALLATION .......................................................................................................................................... 26
7.5.1 Physical mounting ........................................................................................................................... 26
7.5.2 Hazardous Location Compliance ..................................................................................................... 26
7.5.3 Protective Earth Grounding for Non Hazardous Locations.............................................................. 27
7.5.4 Connection to MPM ........................................................................................................................ 27

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page iv
8JUNCTION BOXES AND CABLES ............................................................................................................30
8.1 LIST OF CABLES......................................................................................................................................... 30
8.1.1 Connecting to RSP ........................................................................................................................... 30
8.1.2 Junction Box to sensor..................................................................................................................... 30
8.2 LIST OF JUNCTION BOXES ........................................................................................................................... 31
8.3INSTALLATION .......................................................................................................................................... 31
9SENSORS .............................................................................................................................................32
9.1 LIST OF APPROVED SENSORS....................................................................................................................... 32
9.2 HAZARDOUS LOCATION NON-INCENDIVE SENSORS .......................................................................................... 33
9.3 SENSOR INSTALL LOCATIONS ....................................................................................................................... 33
9.4 INSTALLATION .......................................................................................................................................... 34
9.4.1 Mounting point Preparation ........................................................................................................... 35
9.4.2 Adhesively bonded mounting puck.................................................................................................. 35
9.4.3 Drilled and tapped mount ............................................................................................................... 36
9.5 ACCELEROMETER ATTACHMENT ................................................................................................................... 38
9.5.1 Equipment and materials required.................................................................................................. 38
9.5.2 Installation ...................................................................................................................................... 38
9.5.3 VT-11 ............................................................................................................................................... 38
9.5.4 Removal........................................................................................................................................... 39
9.6 TEMPERATURE RTD’S............................................................................................................................... 39
9.6.1 Equipment and materials required.................................................................................................. 39
9.6.2 Hazards ........................................................................................................................................... 40
9.6.3 Installation ...................................................................................................................................... 40
9.6.4 Removal........................................................................................................................................... 40
9.7 GLAND WATER FLOW METER AND PRESSURE TRANSDUCER.............................................................................. 40
9.7.1 Equipment and materials required.................................................................................................. 40
9.7.2 Possible Hazards.............................................................................................................................. 40
9.7.3 Installation ...................................................................................................................................... 40
9.8 SPEED –PROXIMITY SENSOR ....................................................................................................................... 41
9.8.1 Equipment and materials required.................................................................................................. 41
9.8.2 Hazards ........................................................................................................................................... 41
9.8.3 Installation ...................................................................................................................................... 42
10 CLEANING AND MAINTENANCE ............................................................................................................42
11 REGULATORY COMPLIANCE.................................................................................................................42
11.1 ELECTROMAGNETIC COMPATABILITY............................................................................................................. 42
11.2 HAZARDOUS LOCATION COMPLIANCE ........................................................................................................... 43
11.3 SAFETY ................................................................................................................................................... 44
11.4 RADIO APPROVALS.................................................................................................................................... 44
11.4.1 FCC Requirements for Operation in the United States:............................................................... 45
11.4.2 FCC RF Radiation Exposure: ........................................................................................................ 45
11.4.3 Industry Canada Requirements for Radio Operation in Canada:................................................ 45

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page v
Table of figures
Figure 1-1 Transient Protection Parameters, Line to Line and Line to Ground........................3
Figure 4-1 System diagram......................................................................................................6
Figure 5-1 Iso view of PSM......................................................................................................7
Figure 5-2 PSM Connectors.....................................................................................................8
Figure 6-1 MPM perspective view (cables and protective shroud removed)............................9
Figure 6-2 MPM with connector shroud installed ...................................................................10
Figure 6-3 MPM connector view - protective caps installed...................................................10
Figure 6-4 MPM External dimensions ....................................................................................11
Figure 6-5 Connector view.....................................................................................................11
Figure 6-6 Connector Keying, View from MPM Connector ....................................................12
Figure 6-6 - MPM connector names and locations.................................................................12
Figure 6-7 MPM & PSM generic mounting plate....................................................................13
Figure 6-8 - MPM & PSU installed on mounting plate............................................................15
Figure 6-9 SIM card receptacle in MPM.................................................................................15
Figure 6-10 24Vdc power connection from PSM to MPM ......................................................15
Figure 6-11 Mains AC power connection to PSM ..................................................................16
Figure 6-12 Installation of Locking Clips ................................................................................16
Figure 6-13 Location of Protective Earth Grounding on MPM................................................17
Figure 6-14 Antenna mount attached.....................................................................................18
Figure 6-15 Installation of Antenna(e)....................................................................................19
Figure 6-16 Antenna with and without cable attached ...........................................................19
Figure 6-17 Antenna connector wrapped in protective tape...................................................20
Figure 6-18 Schematic of Wifi and Cellular antennae connections to MPM ..........................20
Figure 7-2 RSP shown with connector shield installed ..........................................................23
Figure 7-3 RSP Physical dimensions.....................................................................................24
Figure 7-4 RSP Connector layout and descriptions ...............................................................24
Figure 7-5 Connector Keying, View from RSP Connector .....................................................25
Figure 7-5 RSP Connector port descriptions..........................................................................25
Figure 7-6 RSP Mounting Dimensions..................................................................................26
Figure 7-7 Location of Protective Earth Grounding on RSP...................................................27
Figure 7-8 MPM Comms + power connector on RSP............................................................28
Figure 7-9 RSP comms + power connectors on MPM...........................................................28
Figure 7-10 PSM, MPM and RSP connected.........................................................................29
Figure 8-1 Installation of Locking Clips ..................................................................................31
Figure 9-1 Sensor Install Locations........................................................................................33
Figure 9-2 Slurry pump installation - mounting puck..............................................................34
Figure 9-3 Triblock mounting accessory ................................................................................34
Figure 9-4 Slurry pump - Mounting pump adhesively bonded to pump..................................36
Figure 9-5 Uni-axial accelerometer with connector and protective tape applied....................38
Figure 9-6 Tri-Block................................................................................................................39
Figure 9-7 RTD.......................................................................................................................39
Figure 9-8 Gland water sensor installation.............................................................................41
Figure 9-9 Speed sensor mount example (new picture required) ..........................................41

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page 1of 46
1 Introduction and Safety
1.1 Introduction
The purpose of this manual is to provide details on how to install the Weir Industrial Gateway
in a generic sense ie independent of product type.
Read this manual carefully before installing and using the product.
1.2 Scope
The three main items covered in this guide are :
oPower supply Module : PSM
oMain Processor Module : MPM
oRemote Signal Processor : RSP
The important specifications of these devices and the basic installation process will be
covered.
1.3 Target Audience
This document is directed towards maintenance fitters, technicians and any staff involved in
installing this system.
1.4 Safety
1.4.1 Safety Terminology and Symbols
You must observe the instructions contained in this manual. Failure to do so could
result in damage to equipment and/or injury or death.
1.4.2 User Safety
Use Personal Protective Equipment (PPE) according to the site regulations for that work
area. This may include,but is not limited to:
oHard hat
oSafety goggles
oProtective shoes
oProtective gloves
oHearing protection
Notice:
Never work on equipment unless the correct lockout procedures have been followed

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
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1.4.3 Warnings
WARNING: THE SAFETY OF ANY SYSTEM INCORPORATING THIS EQUIPMENT IS
THE RESPONSIBILITY OF THE ASSEMBLER OF THE SYSTEM.
WARNING: TO PREVENT FIRE OR SHOCK HAZARD, DO NOT OPEN COVERS. NO
USER SERVICEABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE
PERSONNEL.
WARNING: EXPLOSION HAZARD. DO NOT CONNECT OR DISCONNECT CABLES
WHEN ENERGIZED IN A HAZARDOUS LOCATION ENVIRONMENT. DO NOT
CONNECT OR DISCONNECT ANY CABLES WHILE CIRCUIT IS LIVE OR ULESS THE
AREA IS FREE OF IGNITABLE CONCENTRATIONS.
WARNING: IN HAZARDOUS LOCATION ENVIRONMENTS THE EQUIPMENT MUST
BE OPERATED AT ALL TIMES WITH THE CONNECTOR SHROUDS INSTALLED.
WARNING: DISCONNECTING CABLES IN A HAZARDOUS LOCATION
ENVIRONMENT CAN CREATE A SPARK. CABLES ARE ONLY TO BE
DISCONNECTED BY QUALIFIED SERVICE PERSONNEL.
AVERTISSEMENT: LA SÉCURITÉ DE TOUT SYSTÈME INCORPORANT CET
ÉQUIPEMENT EST LA RESPONSABILITÉ DE L'ASSEMBLÉE DU SYSTÈME.
AVERTISSEMENT: POUR ÉVITER LE RISQUE D'INCENDIE OU DE CHOCS, NE PAS
OUVRIR LES COUVERTURES. AUCUNE PIÈCE DE SERVICE UTILISABLE À
L'INTÉRIEUR. CONSULTER L'ENTRETIEN AU PERSONNEL DE SERVICE QUALIFIÉ.
AVERTISSEMENT: RISQUE D'EXPLOSION. NE PAS CONNECTER OU
DÉCONNECTER DES CÂBLES QUI SONT ENERGISÉS DANS UN ENVIRONNEMENT
DE LOCALISATION DANGEREUSE. NE PAS CONNECTER OU DÉCONNECTER
TOUS LES CABLES, SI LE CIRCUIT EST VIVANT OU ULTÉRIEUR, LA ZONE EST
LIBRE DE CONCENTRATIONS IGNITABLES.
AVERTISSEMENT: DANS LES ENVIRONNEMENTS DE LOCALISATION
DANGEREUSES, L'ÉQUIPEMENT DOIT ÊTRE FONCTIONNÉ À TOUTES LES
HEURES AVEC LE CONNECTEUR SHROUDS INSTALLÉ.
AVERTISSEMENT: LA DÉCONNEXION DES CABLES DANS UN ENVIRONNEMENT
DE LOCALISATION DANGEREUSE PEUT CRÉER UNE SPARK. LES CABLES SONT
SEULEMENT DÉCONNECTES PAR UN PERSONNEL DE SERVICE QUALIFIÉ.

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page 3of 46
1.4.4 Determination That Equipment Can be Used Safely in the Intended Area
The installation of this system requires that the equipment be mounted in such a way that it
can withstand impacts from use and vibration from the machinery it is attached to. The
following should be checked to ensure that the installation is safe:
Cables should be supported such that the supports carry the weight of the cable and
the connectors are not being pulled from the weight of the cable.
In hazardous location areas, the air surrounding the equipment should have an
oxygen concentration of not greater than 21 percent by volume; and a pressure of 80
kPa (0.8 bar) to 110 kPa (1.1 bar)
The ambient temperature range is from -30°C ≤ Tamb ≤ 70°C.
The mains that the equipment is attached to have a 15A circuit breaker installed
outside of the hazardous area for hazardous locations.
All connections are tight and in hazardous location areas, all locking mechanisms on
the connectors are attached.
All connections are watertight, with Nitto No 15 self-amalgamating tape used on the
RF connections to ensure that water cannot get into the connector.
The sensors are installed in such a manner that they will not come off from operation,
and the sensor cables will not interfere with equipment operation. It is preferable that
sensor cables do not get very close to electric motor windings, which can generate
significant amounts of magnetic field, which may affect the sensor sensitivity.
The sensor electrical connections are waterproof.
The transient limiting of lightning, surges, and other transients coming from the mains
power is done within the power supply by the use of transient/surge absorbers. These
are connected line to line, as well as line to chassis ground. The characteristics of these
transient absorbers are as follows:
Part No
Varistor
Voltage (V)
Maximum
Allowable
Voltage
Clamping Voltage
At 8/20µs
Max (V) Ip (A)
Maximum Peak
Current at 8/20µs (A)
1 time 2 times
Panasonic
ERZ-V20D431
430
(387 to 473)
275Vac, 350 Vdc
745
5
800
600
710
10
1750
1250
710
25
3500
2500
710
25
3500
2500
710
50
6000
4500
710
100
10000
6500
Figure 1-1 Transient Protection Parameters, Line to Line and Line to Ground
The Continuous operating temperature of the gaskets are as follows:
<ADD GASKET COT INFORMATION HERE>

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5
Copyright © Weir Minerals Australia Ltd 2017. Commercial in Confidence. All rights reserved. Page 4of 46
2 Transportation and Storage
2.1 Consignment receipt and unpacking
oInspect the package for damaged or missing items upon delivery. All items
should be checked against the delivery note
oNote any damaged or missing items and inform the supplier and relevant
parties
2.2 Transportation Guidelines
oThe gateway and its components are designed to be lifted and man-
transported without cranes or other lifting equipment
2.3 Storage
For long term storage, ensure connector caps are firmly secured on the all gateway
connectors
3 System components
A number of main components are common across many of the product implementations.
These are :
oPower Supply Module (PSM)
oMain Processor Module (MPM)
oRemote Signal Processor (RSP)
Name
Acronym
Description
Power Supply
Module
PSM
24Vdc 500W power
supply for MPM, able to
supply fully loaded
system at extremes of
environmental ratings
Main Processor
Module
MPM
Module that runs the
Node Engine software,
processes data &
connects to the
enterprise