Verax 75 and Verax VPA
Installation Manual
JP3 Measurement
4109 Todd Lane
Austin TX 78744
512-537-8450
www.jp3measurement.com
07/01/2015
Verax Single Ch Installation Manual, Rev H
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Table Of Contents:
1. Facilities Requirements
page 3
2. Unpacking and Handling
page 5
3. Mounting the Control Panel
page 7
4. Mounting the Probe Assembly
page 9
5. Probe Assembly to Control Panel Connections
page 11
6. Z-purge installation (optional)
Page 16
7. Heater Blanket for Probes (optional)
Page 18
8. Power Up and Commissioning
Page 19
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1) Facilities Requirements:
Intended Use:
The Verax 75 is an optical NIR analyzer for determining the constituents and physical
properties of a hydrocarbon fluid stream by using NIR spectroscopy to model the
parameter of interest. Contact a JP3 sales representative to discuss the range of
analysis available. The Verax 75-Z model incorporates a Z-purge system for mounting in
a Class I / Division 2 location.
Location Rating:
•
•
•
•
•
Verax 75 Analyzer is in a Type 4 NEMA Enclosure, and all
provided fittings are Type 4 rated.
For General Purpose Location, Conforms to ANSI/UL Std 610101
For Class I / Division 2 A,B,C,D, T Code- T4 a Type Zpressurization must be used. With Z-purge, Conforms to NFPA
Std 496
Certified to CAN/CSA Std C22.2 No. 61010-1
Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F).
Electrical Input Requirements:
•
•
•
Per Customer Specification one of the two options below:
•
100-240V AC, 50-60 Hz, 1.6-0.7 Amp
•
Or, 24V DC, 3.5 Amp
The input electrical configuration is indicated on the warning tag below the
antenna on the left side of the box (see Figure 3)
For surge protection a 20A breaker is recommended as the customer-provide
disconnection device
Other Facilities Requirements (for Z-purge only):
•
Instrument Air or Nitrogen
•
Supply pressure: 80-120 psig
•
Safe Pressure Set Point: 0.25’ water column
•
Safe pressure flow rate: 0.13-3.5 SCFH
•
Exchange Flow Rate: 4 SCFH
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Explanation of Warning Labels:
The following warning applicable only when using the Z-purge option:
WARNING – PRESSURIZED INCLOSURE
This enclosure must not be opened unless the area atmosphere is known to be below the
ignitable concentration of combustible materials or unless all the devices within have been
de-energized
AVERTISSEMENT : BOÎTIER SOUS PRESSION:
Ce boîtier ne doit pas être ouvert à moins que l'atmosphère de la zone ne soit inférieure à la
concentration inflammable de matières combustibles ou à moins que tous les dispositifs qui
s’y trouvent n’aient été mis hors tension.
The following warning applicable only when using the Z-purge option:
WARNING: Power must not be restored after enclosure has been opened and until enclosure
has been purged for 3.5 minutes for Verax 75-Z model or 6 minutes for Verax 75M-Z
AVERTISSEMENT: L'alimentation ne doit pas être rétablie après l’ouverture du boîtier et
jusqu'à ce que le boîtier ait été purgé pendant 3,5 minutes pour le modèle Verax 75-Z ou
6 minutes pour le modèle Verax 75M-Z.
The following warning applicable to all models:
The model and electrical configuration on the warning label are specified with punched holes
next to the applicable value.
Le modèle et la configuration électrique sur l'étiquette d'avertissement sont spécifiés avec
des trous percés à côté de la valeur applicable
Figure 1: Warning Label
Located on the left side of the
analyzer below the antenna
port. (see Figure 3)
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2) Unpacking and Handling:
Shipped Materials:
• Verax Analyzer Control Panel (qty 1)
• Probe Assembly (qty 1)
• Antenna (qty 1)
• Z-purge w/ fittings (optional, 1 set)
Handling Instructions:
•
•
•
•
Weight:
51lbs
Dimensions:
24’’ x 30’’ x 9.35’’
Mounting Holes:
18” x 31.25”
Uncrate and mount the analyzer to unistrut or other mounting surface capable of
handling the weight of the unit. Do not drop.
24”
18”
9.35”
30”
31.25”
Front View
Side View
Figure 2 – Verax 75 Analyzer Control Panel - Dimensions
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Antenna
Fitting
Serial # &
Warning
Label
Wiring Terminal Blocks
Incoming
Power
Connection
Radio /
Modem
PLC
PC
Ethernet
Switch
(Comm)
RTD and
Transducer
Terminal
Block
Spectrometer
Figure 3 – Verax 75 Analyzer Control Panel – Front View
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3) Mounting the Control Panel:
Mounting Requirements:
•
•
•
•
•
Select a location that is easily accessible at grade level.
Mounting holes are provided for easy installation.
The Probe Assembly must be mounted next to the analyzer – separation is limited by
10 linear feet of fiber.
Shade is required if mounting outdoors where ambient temps can exceed 90⁰ F.
Do not mount the analyzer in such a way to make it difficult to operate the
customer-provided electrical disconnect device (witch, breaker or other)
Antenna Connection:
1.
2.
1.
2.
3.
4.
5.
6.
7.
16dB Antenna is provided along with a 90 degree fitting.
Attach Antenna to the fitting on the upper left of the Analyzer Panel using the 90
degree fitting (see Figure 3 for location of the fitting).
Fiber Optic Connection:
The Fiber is passed through the flex conduit/liquid
tight fittings on the bottom of the analyzer control
panel. Customer provides flex conduit.
Send Fibers will be labeled with 2” Red Shrink Tube
reading “SEND”.
Receive Fibers will be labeled with 2” Yellow Shrink
Tube reading “RECEIVE”.
Pull the fibers through the flex conduit, and let the
excess hang coiled up under the analyzer until
ready to connect to the probe assembly.
Leave the caps on the end of the fiber. Do not let
the fiber drag on the ground.
See Section 5 for instructions to connect the fiber
to the probe assembly
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Figure 4 – Fiber Optic
Cables installed with the
Liquid Tight Fitting and
Flex Conduit
7
Pass-through for Electrical Wires:
• The Verax Control Panel is shipped without holes or wire ways for most of the
incoming electrical service or fiber connections. The only pre-positioned holes are:
• The Antenna fitting (top left), and
• Two fittings for the fiber (bottom left)
• Additional wire pass-throughs will need to be installed by the customer. The
placement of these holes is left up to the customer’s installation teams in order to
provide maximum flexibility to bring the cables and fiber from below or above, and
attach them to the Verax Control Panels with a sufficient size conduit or fitting.
• All connections or fittings chosen by the customer should by rated for Type 4
enclosure.
• After the wires and fibers are run, all ports and pass-throughs must be plugged with
duct putty or some other standard industry practice to assure the sealed integrity of
the enclosure.
• The customer must plan for the following cables when choosing the size and
placement of ports on the Verax Control Panel:
• One Incoming Electrical Cable
• One Incoming communications Cable
• One RTD cable from the probe assembly
• One Transducer cable from the probe assembly
• Read instructions in Section 6 regarding where these fibers/cables attach inside the
control panel before you start cutting holes.
• The customer is responsible to protect the inside of the control panel when cutting
or punching holes for the wire way. DO NOT ALLOW METAL SHAVINGS TO FALL ON
THE ELECTRICAL CONNECTIONS OR COMPONENTS INSIDE THE CONTROL PANEL.
• Contact your local JP3 sales representative to discuss options
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4) Mounting the Probe Assembly:
Placement:
•
•
The Probe Assembly are typically mounted to a unistrut frame, or other solid structure
Probes should be accessible at grade level.
Pressure and Temp Rating:
•
•
All probe windows and probe assemblies are tested to 1500 psi
Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F).
Bypass Probe Configuration:
•
•
•
•
•
•
For a bypass probe assembly, the customer taps into the process stream they want to
monitor, plumbs the fluid to the inlet on probe assembly, and back to the process
stream. (see Figure 4 on the next page)
It is highly recommended that the customer supply a stinger at the inlet and return of
the pipe you are monitoring in order to pull fluid from the center of the pipe.
Either ½” or ¼” Swagelok fittings are supplied on the inlet and return ports of the probe
assembly. Customer supplies ¼” or ½” stainless steel tubing as dictated by the fittings
supplied on the probe assembly.
•
½” is typical for liquids
•
¼” is typical for gas
The customer must assure sufficient flow of liquid or gas over the probe windows by
providing a pressure drop of at least 2 inAq (or 20 SCFH) from inlet to outlet.
Choosing the correct inlet and return points on the process pipe is critical to assure
flow. Often choosing inlet and return points such that flanges, valves, meters or
similar instruments are located between these two points is sufficient to provide the
necessary bypass pressure differential.
Actual Installation details vary by location and application; consult with JP3 Sales
representative to discuss options.
When using a heater blanket with the probe assembly, 120VAC, 2 Amp service is
required. The junction box must be within 4 feet of the probe assembly.
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∆P from Inlet to Return
must be at least 2 inAq
(inches of water)
Inlet
Stinger to sample from
center of the pipe
Return
Figure 5 – Example Probe
Bypass Arrangement
36”
31.7”
21”
Inlet Port
Receive Fiber
Sealcon Fitting
Transducer
RTD
Service Port DO NOT
REOME CAP
Send Fiber
Sealcon Fitting
13.2”
Service Port DO NOT
REMOVE CAP
Conduit Housing
Return Port
4.4”
Top-Down View
Figure 6 – Bypass Probe Assembly
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5) Probe Assembly to Control Panel Connections
Connect Fiber Optics to Probe Assembly:
Warning – Read Carefully
•
•
•
•
Fiber optic cable is extremely sensitive to sharp bend angles and contamination.
Handle very carefully to avoid kinks and keep the ends capped until ready to attach to
the probes.
Maintain a minimum 7” bend radius when running/routing the fiber from control box
to probe assembly
It is recommended that the fiber optic cable be run in it’s own dedicated conduit, or
elevated cable trays. Do not place fiber in ground level open cable trays where it can
be stepped on.
Keep the fiber ends capped until you a are ready to connect the ends.
Attach Fiber to Probe Assembly:
1.
2.
3.
4.
5
Open the conduit housing on the probe assembly
Install the fiber using LT50 fittings and flex conduit at either end of the probe assembly
(see Figure 6). The flex conduit approach offers the best protection for the fiber.
Connect the fiber to the back of the probe inside the conduit housing by screwing the
fiber end onto the threaded probe connection. (see Figure 7)
DO NOT THROW AWAY THE KNURLED CAPS. These should be left in the conduit
housing to be used to protect fiber and probe connections when disconnected during
servicing.
Replace conduit housing cover
Liquid Tight Fitting
Figure 7 –
Fiber Installation on
Probe Assembly
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Fiber/Probe
Connection Point
11
JP3 Measurement Fiber Optic Cable Specification
JP3 uses a custom optical fiber assembly, design and characterized to maximize the
characteristics of the optical loop from laser to probe and back to the detector. The
following are specifications important for handling and installation of the fiber:
•
600um-core multimode fiber with a Kevlar jacket.
•
5.5mm black PVC weather proof furcation jacket, UV resistant
•
Outdoor rated construction, and all components nonconductive
 (most similar to OFNR indoor construction)
•
Weight = 22 lbs/1000 feet
•
Max Installation Tension, 180 lbs (800N)
•
Max Operating Tension, 90 lbs (400N)
•
Installation Temp Range, 15⁰ F to 176⁰ F (-20 to 80 C)
•
Operational temp range, -20⁰ F to 122⁰ F (-29C to 50C)
•
Minimum Bend Radius = 7”
•
Male SMA connections on both ends.
•
Each end will be labeled as below:
Figure 8 –
Fiber Assembly dimensions and labeling
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Wire the Probe Assembly to the Control Panel:
1.
2.
3.
4.
The Analysis Points on the RTD and Transducer terminals are numbered 1-2 from
top to bottom
Run the RTD and transducer cables through customer-provide wire pass through
port and route to the terminal blocks on the left side of the panel.
Connect the RTD cable to number 1 on the RTD terminal block, as shown in
Figure 9:
•
one red wire to the top terminal tier
•
the other red wire to the middle terminal tier
•
the white wire to the bottom terminal tier
Connect the transducer cable to number 1 on the transducer terminal block as
shown in Figure 9:
•
Red wire on the top terminal tier
•
Black on the second terminal tier
•
Brown on the third terminal tier
•
Gray on the bottom terminal tier
Figure 9 –
RTD and Transducer Wiring Instructions
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Connect the Ethernet Communications Cable:
1.
2.
Run the Ethernet communications cable through customer-provide wire pass through
and route to the Ethernet switch on the right side of the analyzer control panel. ( See
Figure 3)
Connect to any available Ethernet port
Connect Main Power:
• For 24V DC Power Configuration
1. Run the power cable through customer-provide wire pass through port and
route to the terminal blocks on the upper right side of the analyzer control
panel. ( See Figure 3)
2. Connect hot wire to 24V fuse
3. Connect neutral wire to 0V terminal
Figure 10 –
Main 24VDC Power Wiring Instructions
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Verax Single Ch Installation Manual, Rev H
Components shown inside
dotted line only included
with100-240V AC option
14
Connect Main Power:
For 100-24VAC Power Configuration
1. Run the power cable through customer-provide wire pass through port and route to
the terminal blocks on the upper right side of the analyzer control panel. ( See
Figure 3)
2. Connect hot wire to 100-240V fuse
3. Connect neutral wire to 0V terminal
4. Connect ground wire to the green/yellow ground terminal
Figure 11 –
Main 100-240VAC Power
Wiring Instructions
07/01/2015
Components shown inside
dotted line only included
with100-240V AC option
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6) Z-Purge Installation (optional):
Warning – Read Carefully
•
You must install the Z-purge if the Verax 75 will be in a Class I / Division 2 Hazardous
location.
Installation:
•
Mounting Configuration and Pipe Routing are shown below in Figures 11 and 12. All
fittings are ¼”
Figure 12 – Pipe Fitting
Schematic, (Viewed from
back of Verax Panel)
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Figure 13 – Z-Purge Hardware
Configuration.
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7) Probe Heater Blanket (optional):
Installation:
•
Heater blankets are designed to wrap around the sample cell cross to keep the probes
warm and free of paraffins.
Electrical:
•
•
•
Heater blankets use Thermon self-regulating 12W/ft heating tape
2Amp, 120V AC electrical service
A 5’ pigtail is provided using ½” flex conduit.
Figure 14 – Heater Blanket
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8) Power-up and Commissioning:
Power Up Sequence:
•
To Engage Power engage the fuses in the following order
1. 100-240V fuse (if applicable – for the AC configuration only)
2. 24V fuse (Power to PLC, Switch)
3. 12V fuse (Powers PC and Radio)
4. 12V fuse (Powers Spectrometer)
Figure 15 –
Power up sequence
4th 3rd 2nd
1st
•
At this point the Verax 75 Analyzer is ready to be commissioned. Contact JP3
Field Service team to complete installation and commissioning.
•
Contact JP3 Field Service team for all maintenance and servicing needs
•
service@jp3measurement.com
•
512-537-8450
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