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Online Electronics 4003 MAGSIG Operating Manual

Non-intrusive pig signaller magnetic topside
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Non-Intrusive Pig Signaller
Magnetic Topside
Operating Manual
The 4003 MAGSIG® is a fully ATEX, IECEx
and CSA/cUL certified, non-intrusive
pig signaller which quickly and
accurately detects, signals and logs the
passage of magnetic pigs at critical points
along a pipeline both on land and offshore
Online Electronics Limited
+ 44 (0) 1224 714714
OEL-Sales@ik-worldwide.com
CHALLENGE
ACCEPTED
online-electronics.com

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Summary of Contents for Online Electronics 4003 MAGSIG

  • Page 1 Non-Intrusive Pig Signaller Magnetic Topside Operating Manual The 4003 MAGSIG® is a fully ATEX, IECEx and CSA/cUL certified, non-intrusive pig signaller which quickly and accurately detects, signals and logs the passage of magnetic pigs at critical points along a pipeline both on land and offshore...
  • Page 2 4003_5001 Date Summary of change 16/05/18 Initial Release 14/09/18 Updates + MODBUS detail 29/10/18 Special conditions and markings updated. 31/10/18 Sections 4.8 & 4.10 updated. 12/12/18 Weights updated 27/06/19 Updates due to firmware changes, affecting menu, and PCB affecting labelling of Interface PCB and power supply/CL. Warnings added with reference to intrinsic safe equipment.

  • Page 3: Table Of Contents

    CONTENTS Page GENERAL DESCRIPTION ..................4 SPECIFICATIONS ....................5 2.1. GENERAL ......................5 2.2. STANDARD OUTPUTS ..................5 2.3. OPTION OUTPUTS ....................5 2.3.1. LoRa Radio Modem ..................5 RULES FOR SAFE OPERATION ................. 6 OPERATION ......................7 4.1. TURNING ON ..................... 7 4.2.
  • Page 4 5.1. BLUETOOTH ENABLE ..................29 5.2. BLUETOOTH CONNECTION ................29 5.3. DEVICE DISPLAY INFORMATION ................ 31 5.3.1. DEVICE CHANGEABLE FIELDS ............... 31 5.3.2. INDICATION ONLY ..................31 5.3.3. LOGGED DATA .................... 31 ROUTINE MAINTENANCE AND STORAGE ..............32 DISPOSAL......................32 WARRANTY ......................

  • Page 5: General Description

    1. GENERAL DESCRIPTION The OnlinE 4003 MAGSIG® is a robust, non-intrusive magnetic pig signaller which detects, signals, and logs the passage of magnetic pigs at critical points along a pipeline both on land and offshore. Events are signalled as they occur via an OLED dot matrix display and high brightness LEDs positioned around the perimeter of the display.

  • Page 6: Specifications

    2. SPECIFICATIONS 2.1. GENERAL External supply ..............+21.6Vdc to +26.4Vdc, <1.0W Loop powered current loop ................... 8- 20mA Temperature range using external supply (NO CELLS FITTED) -50°C to +85°C (-58 to +185°F) Battery type ..............4x DURACELL ID1300 Alkaline cells Battery type ................ 2x SAFT LS33600 Lithium cells Battery life in Listening/Low Power Mode at +20°C ........

  • Page 7: Rules For Safe Operation

    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.

  • Page 8: Operation

    4. OPERATION Familiarise yourself with the rules for safe operation of this equipment as described in Section 3 RULES FOR SAFE OPERATION. The 4003 provides a 2x16 OLED dot matrix display at the front of the unit. A control button is located on the rear of the unit.

  • Page 9: Stabilisation

    4.2. STABILISATION The STABILISATION delay occurs at switch ON only. During the STABILISATION delay the unit will ignore all magnetic events. The LEDs will flash every 5 seconds and the relay and current loop outputs will be in the DETECTION state. The STABILISATION delay can be used during deployment to prevent any unwanted events from being logged due to movement of the unit in the earths’...

  • Page 10: Detection Mode

    4.4. DETECTION MODE There are two DETECTION METHODS. The default PIG PASS mode detects when the PIG has likely to have PASSED the signaller and DETECTION ONLY detects the presence of a pig but not necessarily that it has passed. The latter is useful when trying to determine when a PIG has been launched, where the pig is initially present, and the pig’s movement will be away from the signaller –...

  • Page 11: Detection Delay

    DETECTION event is signalled when the flux reading has peaked and the buffer (at current fill rate) is filled. During DETECTION display shows PIG nnn DETECTED and the LEDs around the display will flash every 1 second and the relay and current loop outputs will be in the DETECTION state. The unit will remain in this state for the length of time defined by the DETECTION delay.

  • Page 12: Single Button Menu Interface

    4.5. SINGLE BUTTON MENU INTERFACE While LISTENING, the control button can be firmly pressed for > 2 seconds to enter the menu interface. While in the menu interface, the unit will ignore all magnetic disturbances including PIG passages. From the menu the user can configure several parameters which are discussed in this section.
  • Page 13 When an editable menu item has been selected a ‘>’ will appear in the bottom left corner of the display to indicate that the selected menu item is now in edit mode and the button may be released. LONG PRESS TO The cursor will blink to indicate the field ENTER EDIT MODE currently being edited.

  • Page 14: View Events

    4.5.1. VIEW EVENTS Selecting this item will allow the user to cycle through all logged EVENTS from newest to oldest. The peak DIFFERENCE flux reading, EVENT number, and EVENT date and time are shown. Firmly pressing the CONTROL BUTTON momentarily will cycle to the next event. If the control button is not pressed for 30 seconds, or if the user cycles beyond the last recorded event the unit will return to LISTENING mode.

  • Page 15: Date

    4.5.7. THRESHOLD CAUTION: Adjusting this parameter without first consulting Online Electronics Ltd may cause the unit to miss pig passages or give false detections. Selecting this item allows the THRESHOLD level to be configured to control the sensitivity of the unit.

  • Page 16: Auto Power Off

    4.5.12. AUTO POWER OFF Selecting this item allows the AUTO POWER OFF function to be configured. It is possible to configure any number of days from 01 to 28. The AUTO POWER OFF timer will be ENABLED immediately once any non-zero value is set. While ENABLED, each time the unit is powered ON the AUTO POWER OFF timer will restart and the unit will automatically shut down after the configured number of days has elapsed.

  • Page 17: Bluetooth

    4.5.17. BLUETOOTH Selecting this item allows the Bluetooth module to be ENABLED or DISABLED. The Bluetooth module should be disabled when not required as the module draws significant power from the batteries which will reduce the battery life of the unit. Refer to Section 5 BLUETOOTH INTEGRATION 4.5.18.

  • Page 18: Exit Menu

    4.5.25. EXIT MENU Selecting this item will EXIT the menu interface and the unit will resume LISTENING. 4.6. MODBUS RTU RS485 INTERFACE Communication to the 4003, via the RS485 interface, makes use of MODBUS protocol as defined in MODBUS OVER SERIAL LINE V1.02 published by the MODBUS organisation. The communication parameters adhere to this standard using the default RTU transmission mode.
  • Page 19 RELAY LOGIC 10004 Enable Remote Sensor Remote sensor selected when set 10005 Enable SD Card Logging 10006 Enable LED Flash Refer to Section 4.5.16 LED FLASH 10007 Enable Bluetooth 10010 Pig Approach Indication Reference section 4.4 INPUT REGISTERS 30000 Serial Number Serial number of unit 30001 DOMyy...
  • Page 20 40018 Sensor Output 40019 Status OEL Use Only 40020 Detection Type 0 = Peak Value – 50% 1 = Peak Value – 25% 2 = Peak Value – 10% 3 = Peak Value – 5%, 4 = Detection Only Reference section 4.5.11 4003_5001_D02 Page 19 of 35...

  • Page 21: Event Logging And Sd Card

    4.7. EVENT LOGGING AND SD CARD 4.7.1. EVENT LOGGING The signaller contains EEPROM memory capable of recording 127 records of EVENT data as well as other data including time, date and peak flux. These logged EVENTS occur on each DETECTION (and non-detections EVENTS in PIG PASSED detection method) and are retained until erased.

  • Page 22: Mounting

    4.8. MOUNTING Normally the unit is used to confirm whether or not a pig has passed a known point of interest in a pipeline such as a bend or valve. Ideally the unit should be mounted approximately 5m after the point of interest. If the unit is mounted too close then it may detect the pig before the pig has passed safely through the point of interest.

  • Page 23: Battery Replacement

    4.9. BATTERY REPLACEMENT The unit will shut down when the battery voltage reaches 4.0V. To replace the batteries, follow the steps below: The Special Conditions for Safe Use detailed in Section 9 SAFETY INSTRUCTIONS of this manual must be observed always. Only the cell type stated should be installed in the unit.

  • Page 24: External Connections

    4.10. EXTERNAL CONNECTIONS To access external connections, follow the steps below: The Special Conditions for Safe Use detailed in Section 9 SAFETY INSTRUCTIONS of this manual must be observed at all times. Remove the ENDCAP and INTERNAL ASSEMBLY as described in Section 4.9 of this BATTERY REPLACEMENT manual to reveal the external connections as shown.

  • Page 25: Relay Output

    The unit will consume 16.0mA ±1.0mA when in the LISTENING state (refer to Section 4.3 LISTENING). The unit will consume 20.0mA ±1.0mA when in the DETECTION state (refer to Section 4.4 DETECTION MODE). Online Electronics suggest a current loop trigger level of 18mA. 4.11. INTERNAL HEATER WARNING: REFER TO SECTION 9 SAFETY INSTRUCTIONS.

  • Page 26: Rtc Backup

    A separate 2 pin terminal block (EXT+ & EXT-) is provided to connect external voltage to the heater. The heater has a maximum applied supply voltage of 26V although typically 24V should be applied. The power dissipation (Pd) stated on the marking label can be taken as the power rating of the heater element.

  • Page 27: Lora

    The following describes operation using the default communication format and with the Online Electronics LoRa Base Station. The Online Electronics LoRa Base Station is a USB powered unit with antenna. The unit appears as a virtual COM PORT set to 115200BAUD, No Parity, 8 Bits and 1 Stop Bit.
  • Page 28 1, battery voltage of 4003 is 4.2V, Rssi of -48dBm and SNR of 7. An optional ‘verbose mode’ is available on the Online Electronics LoRa Base Station which outputs a serial string with the same information but in a human readable format. The final “ACK sent”...

  • Page 29: Recommended Magnet Arrangement

    4.14. RECOMMENDED MAGNET ARRANGEMENT Refer to the table below for recommended quantities and type of magnets required for pipeline diameter and wall thickness. The magnets should be spaced equally around the pig body with all magnets oriented with the same poles facing outwards e.g. all north poles facing outwards (as shown) or all south poles facing outwards.

  • Page 30: Bluetooth Integration

    16” 13.2mm NdFeB N35 ø48x18mm 5. BLUETOOTH INTEGRATION The 4003 Bluetooth Application is designed for operation on any Android Device with an Operating system of Lollipop or greater. The application is designed to address the Modbus registers and coils to allow data collection and programming changes to be performed in an easy familiar manner.
  • Page 31 4003_5001_D02 Page 30 of 35...

  • Page 32: Device Display Information

    5.3. DEVICE DISPLAY INFORMATION Referring to the graphic above, at the very top of the screen, BATTERY LEVEL, SIGNAL STRENGTH, CONNECTION STATUS and the ANDROID MENU will be displayed. If you select the ANDROID MENU function, a window will open that indicate the following: 1.

  • Page 33: Routine Maintenance And Storage

    6. ROUTINE MAINTENANCE AND STORAGE All Online Electronics Ltd products are designed to require minimum maintenance. The housing should be cleaned using fresh water and cleaning agents as necessary. If the unit is to be placed in storage for a long period of time ensure the unit has been cleaned, turned OFF and main batteries removed.

  • Page 34: Safety Instructions

    9. SAFETY INSTRUCTIONS SPECIAL CONDITIONS FOR SAFE USE: Do not open when an explosive gas atmosphere may be present. Potential electrostatic charging hazard. The equipment should not be mounted in areas where it could be subjected to highly efficient charging mechanisms, such as fast moving dust or particle filled air, and shall only be cleaned with an anti-static or damp cloth.
  • Page 35 16. As part of the routine maintenance schedule, the condition of the window cement shall be periodically inspected for any degradation or dis-colouration of the cement that may compromise the explosion protection. 17. None of the flame paths present on the enclosure are intended to be repaired. 18.
  • Page 36 DECLARATION OF CONFORMITY This declaration of conformity is issued under the sole responsibility of the manufacturer: Online Electronics Ltd Online House Blackburn Business Park Woodburn Road Blackburn Aberdeen AB21 0PS UNITED KINGDOM Object of declaration: 4003 Magnetic Pig Signaller With the following markings with the sensor inside the unit: II 2(1) G Ex db [ia Ga] IIC T4…T6 Gb...

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