Kimray K500 Instruction Manual ENG-017 Rev. 1 Kimray, Inc. Kimray, Inc. provides this publication “as is”, without warranty of any kind, either express or implied, including, but not limited to, the implied warranties of merchantability or fitness for a particular purpose. Information in this publication is subject to change without notice. For current revision go to : http://www.kimray.com:8100/Public/Literature/Automation © 2005 – 2006 Kimray, Inc. All rights reserved. Table of Contents Page 3 1 Introduction .......................................................................................................................... 5 1.1 RTU Overview ............................................................................................................... 5 1.2 Hardware......................................................................................................................... 8 2 Installation............................................................................................................................ 9 Introduction .............................................................................................................................. 9 2.1 Unpacking & Inspection .............................................................................................. 9 2.2 Layout of the K500 Electronics Boards .................................................................... 11 2.3 Standard and Optional Items.................................................................................... 14 2.4 Wiring ............................................................................................................................ 14 2.5 Mounting the K500 ..................................................................................................... 14 2.6 Wiring to the Charger Card ....................................................................................... 16 2.7 Wiring to Multi-variable CIMs and I/O CIMs ...................................................... 16 2.7.1 RS-485 ................................................................................................................... 16 2.7.2 RS-485 Transmission Line Termination ........................................................ 17 2.7.3 Configurations .................................................................................................... 17 2.7.4 RS-485 Connections ........................................................................................... 18 2.7.5 Selection of Transmission Line ....................................................................... 19 2.7.6 Cable Length ....................................................................................................... 19 2.7.7 Addressing .......................................................................................................... 19 2.8 Mounting a Radio ....................................................................................................... 19 2.8.1 Radio Power Cycling ......................................................................................... 20 2.9 Using the Short Range Radio .................................................................................... 21 2.10 Mounting the Battery .............................................................................................. 21 2.11 Mounting the Solar Panel ...................................................................................... 22 2.12 Power.......................................................................................................................... 24 2.12.1 Description of the Charger Card Terminals ................................................. 25 2.12.2 Description of the K500 Main Card Power Terminals ............................... 25 2.12.3 Power Interconnections .................................................................................... 26 2.12.4 Connecting Ground Wiring ............................................................................. 26 2.13 RTD Installation ...................................................................................................... 28 2.14 Connecting Your Computer ................................................................................... 30 3 Inputs and Outputs ........................................................................................................... 33 Introduction ............................................................................................................................ 33 3.1 Description ................................................................................................................... 33 3.2 Discrete (Digital) I/O Card ........................................................................................ 33 3.3 Analog Input Card ...................................................................................................... 34 3.4 Installing an I/O Card................................................................................................. 34 3.5 I/O Wiring ..................................................................................................................... 35 3.5.1 Analog Inputs ..................................................................................................... 35 3.5.2 Discrete Inputs ................................................................................................... 36 3.5.3 Discrete (Digital) Outputs................................................................................ 36 3.5.4 Pulse (Accumulator) Input ............................................................................... 39 3.5.5 LED’s .................................................................................................................... 40 3.6 K500 Multivariable Sensor ........................................................................................ 40 3.6.1 Description of Sensors ...................................................................................... 40 3.6.2 Process Connections .......................................................................................... 41 3.6.3 Sensor Wiring ..................................................................................................... 41 3.7 K500 Turbine Meter Input ......................................................................................... 41 © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 4 Table of Contents 4 Calibration .......................................................................................................................... 43 Introduction.................................................................................................................... 43 Required Test Equipment ........................................................................................... 43 Meter Maintenance Mode ........................................................................................... 43 Absolute Pressure Measurement ............................................................................... 43 4.1 Calibrating Static Pressure ........................................................................................ 44 4.2 Calibrating Differential Pressure (DP) ................................................................... 46 4.3 Returning the Multivariable to service ................................................................... 49 4.4 Using a Five Valve Power Pattern Manifold ......................................................... 50 4.5 Using a Five Valve Gas Pattern Manifold .............................................................. 51 4.5.1 Calibrating Static Pressure (SP) ...................................................................... 51 4.5.2 Calibrating Differential Pressure (DP) .......................................................... 53 4.5.3 Returning the Multivariable to service ......................................................... 55 4.6 Calibrating Flowing Temperature (RTD) ............................................................... 56 4.7 Zeroing Input ............................................................................................................... 56 4.8 Calibration Menus ...................................................................................................... 56 Entering Atmospheric Pressure .................................................................................. 57 Calibrating a Sensor ..................................................................................................... 57 Calibration Methods..................................................................................................... 59 Resetting Calibration ................................................................................................... 59 Calibration Screem ....................................................................................................... 60 4.9 Temperature Calibration Example........................................................................... 61 5 RTU Startup........................................................................................................................ 67 5.1 Initial Startup and Configuration ............................................................................ 67 6 Meter Maintenance Mode ............................................................................................... 69 Introduction ............................................................................................................................ 69 7 Radio Power Cycling and Sleep Operation ................................................................. 73 Introduction ............................................................................................................................ 73 7.1 Sleep Mode Operation ............................................................................................... 73 7.1.1 Sleep Mode Setup .............................................................................................. 73 7.2 Radio Power Switch Mode Operation .................................................................... 73 7.2.1 Daily Power Switch Mode Setup .................................................................... 74 7.2.2 Cycle radio power after inactivity Setup ....................................................... 77 7.2.3 Cryout ................................................................................................................... 77 7.2.4 Tank Stick Power Cycling Setup .................................................................... 78 Appendix A - Specifications .................................................................................................... 81 POWER .................................................................................................................................... 81 MEMORY ................................................................................................................................. 81 ENVIRONMENT...................................................................................................................... 81 DISCRETE (DIGITAL) INPUT .............................................................................................. 81 DISCRETE (DIGITAL) OUTPUT .......................................................................................... 81 ACCUMULATOR INPUT ....................................................................................................... 82 ANALOG INPUT ..................................................................................................................... 82 COMMUNICATION ................................................................................................................ 82 I/O RATINGS ........................................................................................................................... 82 Appendix B: Plunger Lift ........................................................................................................ 83 Appendix C: Switching current in a solenoid ..................................................................... 87 © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 5 1 Introduction This manual provides information necessary to install and setup a K500 RTU 1.1 RTU Overview The K500 is a microprocessor-based Remote Terminal Unit (RTU) that provides functions required for Electronic Flow Measurement (EFM) and Control for up to eight meter runs. The K500 provides the functions required for orifice metering by measuring the differential pressure, static pressure, and temperature with Kimray Multivariables and provides functions required for turbine metering by measuring the pulse counts, static pressure, and temperature. The functions required for measurement and control are provided by optional Discrete (Digital) I/O and Analog Input Cards and Kimray I/O CIMs. The K500 computes gas flow for both volume and energy. The K500 provides onsite functionality and supports remote monitoring, measurement, data archival, communications, and control. The K500 design allows you to configure specific applications including those requiring gas flow calculations, data archival, and remote and local communications. The K500 offers the following features: Full Production Control with PROcontrol Expandable with an RS-485 port – Distributed architecture allows I/O CIM modules to be placed where they are needed, reducing field wiring. Microprocessor with 512Mbyte of flash ROM and 512Mbyte battery backed static RAM memory 2x40 Character Display option 8-run Flow Computer (four orifice & four turbine) with optional integral multi-variable transmitter or external multi-variable transmitters with built-in Resistance Temperature Detector (RTD) Input Temperature Compensated Charger Operator Interface (LOS) Local Port Host Communications Port supporting Kimray and Modbus and protocols RTU Initiated Communications for Exception reporting CMOS Ultra Low Power Design for solar powered applications Power Switching of Communications Devices to conserve power Power Switching of Tank Level Probe to conserve power Extensive applications firmware © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 6 K500 Installation Manual Flexible and Cost Effective Optional I/O: Discrete I/O card with the following 4 Discrete Inputs 1 High Speed Pulse Input with selectable filtering 3 Discrete Outputs Analog Input card with the following 2 Analog Inputs, 1-5V or 4 – 20mA Input CIMs for Expansion * I/O CIM • 2 Analog Inputs • 2 Digital Inputs • 1 Analog Output • 3 Optional Digital Outputs • Optional Turbine Meter Preamplifier • RS-485 Serial Communications Port EPC CIM • 2 Digital Inputs for full open and full closed switches • 2 Digital Outputs to control EPC position • RS-485 Serial Communications Port PULSE CIM • Turbine Meter Preamplifier • RS-485 Serial Communications Port © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 7 Physically, the K500 consists of a printed-circuit Main Electronics Board and a display housed in a compact, weather-tight case. The K500 is packaged in a National Electrical Manufacturer’s Association (NEMA 4) windowed enclosure that can mount on a wall or a pipestand (refer to Figure 1-1 K500). Figure 1-1 K500 © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 8 K500 Installation Manual The enclosure protects the electronics from physical damage and harsh environments. The enclosure consists of two pieces: the body and the door. A gasket seals the K500 when the hinged door is closed. The door secures with lockable hasps. The enclosure is fabricated from either aluminum or carbon steel. Refer to Figure 2-1 K500 Outline and Mounting Dimensions, and Figure 2-2 K500 Steel Enclosure Outline and Mounting Dimensions, for dimensional details. 1.2 Hardware The K500 consists of the main Processor Card. In addition, an Optional Discrete (Digital) I/O Card, Analog Card Charger Card, Communication Card and Display are available for expansion. There are two versions of the Discrete (Digital) I/O card available: One with relays and one with solid state switches. There are also two versions of the Communication Card available: One with a RS-232 interface and one with an embedded short range radio. Figure 2-3 K500 Layout shows the K500 with the optional cards attached and the locations of the terminal barriers. The K500 Electronics Board mounts on stand-offs located on the door except for the steel enclosure version with no display. With the no display option, the Electronics Board mounts on a backplane inside the enclosure. The Main Electronics Board has an LCD display port for an optional display. The I/O parameters, sensor inputs, flow calculations, power control, security, and Production Control programmability are configured and accessed using either the Kimray IMI program or a terminal program such as Kimray’s VbTerm. Some of the Production Control functions that can be programmed are : 1. Turn the Production Control module on or off. 2. Edit the Production Valve parameters. 3. Edit Permanent Shut Down/Temporary Shut Down parameters. 4. Edit/Start Production Volume Control. 5. Edit Optimization and Intermitter parameters. 6. Edit Lift Control parameters. 7. Edit Lift Autotune parameters. 8. Edit Flow Control parameters. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 9 2 Installation Introduction This Chapter provides you with the information for installation and setup. By the time you finish this chapter you will have the RTU unpacked, installed, field wired and ready for operation. 2.1 Unpacking & Inspection The K500 is shipped in a shipping carton which contains the K500 along with optional items such as the U-Bolt Kit, battery cable, communications cables and coax and an RTD with cable. Carefully remove the items from the carton. Inspect the shipping carton for damage. If the shipping carton is damaged, keep it until the contents have been inspected for damage. Inspect the K500 exterior for dents, chipped paint, etc. Inspect the LCD window (if you have the display option) for breakage. Open the housing by releasing the latches. Visually inspect the circuit board, cables, and connectors for damage. If any components have been damaged or if there are noticeable defects, notify your Kimray representative and the shipping carrier. Keep all shipping materials for the carrier's inspection. Kimray will arrange for immediate repair or replacement. Following are dimensional drawings (Figure 2-1 K500 Outline and Mounting Dimensions, and Figure 2-2 K500 Steel Enclosure Outline and Mounting Dimensions) to aid in your installation. The steel enclosure of Figure 2-2 is available with or without the display. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 10 K500 Installation Manual 5.087 13.50 2.83 10.625 21.5 18 HL Figure 2-1 K500 Outline and Mounting Dimensions © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 14 2.825 5.888 Page 11 6 16.75 20.25 HL 11.2 Figure 2-2 K500 Steel Enclosure Outline and Mounting Dimensions (Shown without the optional display) 2.2 Layout of the K500 Electronics Boards The Layout of the K500 is shown in Figure 2-3, K500 Layout with the Charger card, the Discrete (Digital) I/O (DIO) card, the Analog Input (AI) card and the RS-232 Communication card attached. These cards are attached to the inside of the door of the K500 (or to a backplane with the steel enclosure with no display option). © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 12 TB1 V+ ACC+ ACC- JP1 ACCUMULATOR INPUT K500 Installation Manual LITHUM BATTERY GND DIGITAL OUTPUTS ONC ONO OCOM 1COM 1NO DIGITAL INPUTS FLASH 1NC 2COL OPTIONAL CHARGER CARD DI0 DI1 DI2 DI3 GND Kimray K500 DIGITAL I/O CARD TB2 JP1 0+ 0+ 001+ 1+ 1- JP2 1- KIMRAY KIMRAY ANALOG INPUT CARD ANALOG INUTS ANALOGINPUTS ANALOG INPUTS KIMRAY RS232 GND BATT GND GHGR GND OUT XMIT RECV GND BATT GND AUX 485- 485+ GND SAUX PERIPH IN COMM PORT PWR OUT MAIN ELECTRONICS CARD DISPLAY PERIPH (LOS) Figure 2-3 K500 Layout The K500 has a display interface to drive an optional character Liquid Crystal Display (LCD) display. It includes a temperature compensated bias circuit to keep the contrast adjusted over ambient temperature variations. Figure 2.4 K500 Display shows the connection of the display to the Processor Card. The display interface connector is on the back side of the card. The display can either attach directly to the back side of the Processor card for door mounting or can be connected with a ribbon cable to the top of the card. The potentiometer by the connector controls the contrast. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual GND BATT GND GHGR GND OUT XMIT CONTRAST ADJUSTMENT Page 13 RECV DISPLAY CONNECTOR (Connector on back side of card with pins on top side) DISPLAY PERIPH GND BATT GND AUX 485- 485+ GND SAUX FIGURE 2-4 K500 Display The K500 has an optional short range radio card that can be used in place of the RS-232 Communications interface card shown in Figure 2-3 attached to the Main Electronics Card. The Short Range Radio Card is shown in Figure 2-5 K500 Radio Card. It attaches to the Main Electronics Card in place of the RS-232 Card. JP1 JP2 Kimray FIGURE 2-5 K500 Radio Card © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 14 2.3 K500 Installation Manual Standard and Optional Items The K500 can be ordered with the following items for ease of installation: U-Bolt Kit Battery Cable with ¼” Bolt Lugs or with Push-On Tab Lugs Communication Data Cable Communication Coax Cable Polyphaser for Communication Coax Cable RTD With 8ft or 10ft cable The Customer provides the following items for installation: Battery 2-inch pipe for pipe mounting Solar Panel or other charging source Manifold, tubing and fittings Enclosure entry fittings 2.4 Wiring All process wiring to the K500 terminates in the modern version of terminal strip called a "compression screw solderless connector". This form of connector requires no soldering or lug to be placed on the end of the wire, but instead uses a "bare wire" termination technique. "Bare wire" terminations have been shown to be generally superior to the use of ring or spade lugs hand compressed to the ends of signal wires and terminated with screw terminals. The bare wire termination usually results in corrosion resistant "cold flow gas-tight seals"; the hand compression lug terminations usually do not. Bare wire terminations are also much faster to install. The recommended technique for bare wire terminations is very simple: strip 1/4" of insulation from the end of the wire, insert into an open termination slot, and turn the compression screw tight with hand pressure using a pocket screwdriver. Note: Make sure you don’t push the wire’s insulation into the termination slot and don’t allow bare conductors to be exposed. 2.5 Mounting the K500 The K500 must be mounted vertically with the optional Internal Multivariable Sensor (MVS) at its base. It can be mounted using either of the following methods: Pipe mounting - The enclosure provides top and bottom mounting flanges with holes for 2-inch pipe clamps (U-bolts optional). The 2-inch pipe can be mounted to another pipe or meter run with a pipe saddle, or it can be cemented into the ground deep enough to support the weight and conform to local building codes. Note: A Pipe Saddle and 2 inch pipe are not supplied by Kimray. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 15 Do not mount the K500 with the MVS supporting its entire weight due to the weight of the K500 with battery and possibly a radio. HL LOW SIDE HIGH SIDE ORIFICE FITTING RTD PROBE METER RUN SADDLE FIGURE 2-6 DACC500 Mounting and Connections Pipe Mounting Instructions 1. Position pipe saddle on meter run. 2. Temporarily attach the pipe saddle to the meter run pipe using saddle mounting bolts and associated hardware. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 16 K500 Installation Manual 3. Screw 2 inch mounting pipe into pipe saddle and vertically align with level against pipe. 4. After vertical alignment, tighten saddle mounting bolts. Wall or panel mounting - Fasten to the wall or panel using the mounting flanges on the enclosure. Use 5/16-inch bolts through all four holes. Mounting dimensions are given in Figures 2-1, and 2-2. MVS Tubing Instructions With either mounting method, the pressure inputs must be piped to the process connections on the MVS. The following steps to install tubing should be used for the internal MVS: 1. Install isolation valves on meter run 2. Install manifold on K500 3. Install stainless steel tubing to meter run and manifold. 4. Leak check all connections Note: The manifold, stainless steel tubing and tubing fittings are not supplied by Kimray The MVS sensing lines require a downward slope toward the primary meter with a minimum slope of 1 inch per foot of length. The gauge lines shall be supported sufficiently to prevent any observable sag and vibration. The gauge lines shall have a minimum nominal outside diameter of 0.5 inches and a minimum wall thickness of .049 inches Refer to Figure 2-6 K500 Mounting and Connections. 2.6 Wiring to the Charger Card When wiring to the Charger Card, disconnect the power terminal strip from the K500 card (the terminal with GND, BATT, GND, and AUX signals). After all the wiring to the terminal strips (Battery, Charger, Radio etc) is finished, then attach the power terminal strip to the K500 card and the K500 should start operating (refer to section 5 for Startup procedures). 2.7 Wiring to Multi-variable CIMs and I/O CIMs 2.7.1 RS-485 The CIMs are connected to the K500 with an RS-485 interface. RS-485 is a standard for electrical characteristics of transmitters and receivers for use in balanced digital multipoint systems. The RS-485 Standard permits a balanced transmission line to be shared in a party line mode. As many as 32 driver/receiver pairs can share a two-wire party line network. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 2.7.2 Page 17 RS-485 Transmission Line Termination The two-wire party line RS-485 network should be terminated with a termination resistor at the ends of the multidrop network. One method of terminating is to place the termination resistor directly across the line. The termination resistor should match the characteristic impedance of the transmission line, usually in the range of 100 to 120 ohms. Another lower power method of terminating the network is to AC couple the termination resistor to the line. This reduces the amount of DC power required to bias the line in the idle condition and is the type of termination used by Kimray. The K500 end of the transmission is already terminated. The Kimray CIMs have a jumper which will enable the termination resistor (the optional internal MVS doesn’t have a termination resistor jumper because it is not needed if the RS-485 line doesn’t go anywhere else but from the K500 to the MVS). 2.7.3 Configurations The optimal configuration for the RS-485 bus is the daisy-chain connection from node 1 to node 2 to node 3 to node n. The bus forms a single continuous path, and the nodes in the middle of the bus must not be at the ends of long branches, spokes, or stubs. The Diagram below is an example of the proper configuration. Note that the transmission line is terminated on both ends of the line but not at drop points in the middle of the line. The termination at the K500 end is always enabled. The termination at the other end of the line can be made with the jumper on the termination card of the MVS or the jumper on the Kimray I/O CIM. If it is another type of RS-485 device, a 120 ohm resister should be placed between the 485+ and 485- lines. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 18 K500 Installation Manual 2.7.4 RS-485 Connections Figure 2-7 illustrates connecting the K500 to a Multivariable Sensor (MVS). The terminal labeled 485- is connected to the 485- of the MVS, the 485+ terminal is connected to the MVS 485+ terminal, GND is connected to the MVS GND terminal and the MVS V+ terminal can be connected either to the K500 SUAX or the AUX terminals. The SAUX provides power that can be switched OFF most of the time to conserve power. It is then switched ON for a brief period while communicating with a tank probe and then is switched back off. The setup for the tank probe power switching is discussed in Section 7.2.4. If this terminal is used for the MVS it should be programmed to not switch power. K500 MAIN ELECTRONICS CARD GND BATT GND AUX MVS CIM 485-485+ GND V+ 485485+ GND SAUX FIGURE 2-7 MVS RS-485 CONNECTIONS Figure 2-8 illustrates connecting the K500 to a MVS and to a Tank Probe. The terminal labeled 485- is connected to the 485- of the MVS, the 485+ terminal is connected to the MVS 485+ terminal and GND is connected to the ground terminal. In this case AUX terminal provides the power out to the MVS and is connected to the MVS V+ terminal. To connect to the Tank Probe, connect 485to the tank probe RX- and TX/RX- terminals. Connect 485+ to the tank probe RX+ and TX/RX+ terminals. Connect GND to the DC GND terminal and connect the K500 SAUX terminal to the 12VDC terminal. Remember to setup the switching of the SAUX power as discussed in section 7.2.4. K500 MAIN ELECTRONICS CARD GND BATT GND AUX 485485+ GND SAUX MVS CIM 485485+ GND V+ TANK PROBE RXRX+ DC GND 12VDC TX/RXTX/RX+ FIGURE 2-8 MVS AND TANK PROBE RS-485 CONNECTIONS © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 2.7.5 Page 19 Selection of Transmission Line The RS-485 standard specifies only the driver and receiver characteristics, not the transmission line. The most common and the recommended interconnection is to use twisted-pair cable. Any wire gauge can be used. The characteristic impedance of the cable should be 120 ohms, but cables with impedance down to 100 ohm may be used. Examples of cables which can be used are Belden 3082A, 3084A, 3086A, and 3087A. These cables have two pairs. One pair for power and one pair for the RS-485 line. 2.7.6 Cable Length The transmission distance is up to 4000 ft. (1200m). 2.7.7 Addressing Each of the devices attached to the K500 RS-485 bus must have a unique address. The Kimray MVS CIM and the Kimray I/O CIM are shipped with default addresses (1 for the Multivariable CIM and 10 for the I/O CIM). If more than one CIM of the same type is used, the CIM address must be changed to a unique value (Refer to the Kimray CIM Addressing Application Note for instructions on changing addresses). 2.8 Mounting a Radio A radio up to 2.9 inches high can be mounted inside the K500 enclosure using the radio shelf at the top of the enclosure. This shelf allows most radios to be placed in the compartment. Figure 2-12 Radio and Battery Installation shows a typical installation. Route the radio antenna cable to the left rear of the shelf and then out the bottom of the shelf to the bottom of the K500 enclosure. Connect the cable to the Polyphaser (Kimray recommends Polyphaser model IS-B50LN-C2 or equivalent) mounted in the bottom of the enclosure (if the K500 was ordered with the Polyphaser option, the Polyphaser will be preinstalled). Connect the Polyphaser connection on the outside of the enclosure to your antenna. Note: For some radios, the frequency range of the radio is outside of the range specified for the polyphaser and another type of surge suppressor should be selected. Connect the communication cable (a choice of three cables may optionally be ordered with the K500) to the DSUB connector on the K500 RS-232 Communications Card. Route the cable from the door to the main enclosure and up through the rear of the shelf. Then connect the cable to the radio. (Refer to Figure 2-9 Radio Wiring Diagram). Many radios do not require the RTS and CTS lines shown in Figure 2-9. They are optional with the MDS 9810 and not required on the MDS transnet Radio for example. The coax connector shown in Figure 2-9 may be a type N or a TNC, SMA or RPSMA. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 20 K500 Installation Manual K500 MAIN ELECTRONICS CARD DB25 CONNECTOR TYPICAL RADIO GND TXD 2 RTS 4 RXD COAX CONN COAX CONN GND 5 CTS 3 CTS TXD RTS RXD 5 9 4 8 3 7 2 6 1 RADIO ANTENNA CABLE TYPE N POLYPHASER PWR 7 IN OUT S GND GND BATT GND AUX 485485+ GND SAUX 12V K500 RS-232 COMMUNICATIONS CARD K500 ENCLOSURE BOTTOM TYPE N ANTENNA MALE DB9 CONNECTOR COMMUNICATION CABLE Figure 2-9 Radio Wiring Diagram 2.8.1 Radio Power Cycling The Kimray K500 controls a power switching function to cycle radio power for power conservation. A jumper on the RS-232 Communications Card (JP1) converts the sleep mode function into a power switching function. When the sleep signal is activated and the jumper is installed, the power to the radio is switched off. During the wake period power is switched back on. Figure 2-10 K500 RADIO POWER SWITCH shows the sleep mode/power control circuitry for the K500. The sleep signal is on pin 9 of the COMM port connector. With the jumper installed (JP2), when the sleep signal is 0 the switch shown is OFF and power to the radio is OFF. When the sleep signal is at 12 volts, the switch is closed and the radio power switches on (Refer to section 7 for a description of setup for power switching and sleep). © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual SIGNALS GND RI DTR CTS TXD RTS RXD DSR DCD Page 21 J2 5 9 4 8 3 7 2 6 1 -> <-> <<-> -> -> SLEEP CTS TXD RTS RXD TB1 BATT IN SW OUT O O JP1 2 1 RADIO POWER ON JP1 FIGURE 2-10 K500 RADIO POWER SWITCH 2.9 Using the Short Range Radio The Short Range Radio Card described in section 2.2 is typically used to communicate with another RTU. An RTU such as the DACC2000 could for instance communicate with the Modbus version of the K500 to get tank information or to get tubing and casing pressure from a wellhead. Jumper JP2 on the Card (Refer to Figure 2-5 K500 Radio Card and Figure 2-11 below) is used so select either 3.3 volt operation or 5 volt operation depending on which version of the Maxstream radio is used. The XCite uses 3.3 V. while the XStream uses 5.0 V. The XCite is for use for up to 1000 ft. while the XStream is for up to 20 miles. 5.0 V 3.3 V FIGURE 2-11 K500 RADIO CARD JUMPER POSITION 2.10 Mounting the Battery A battery provides the RTU with it’s operating power. The battery is not © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 22 K500 Installation Manual included in the K500 RTU. The battery should be a rechargeable sealed lead acid battery. A battery up to 8½ inches high can be mounted inside the K500 enclosure using the U shaped battery shelf at the bottom of the enclosure. This shelf allows most batteries up to 50 A-H or more to be placed in the compartment. Figure 2-12 Radio and Battery Installation shows a typical installation using the Power Sonic PS12400, 40 AH battery . The wiring of the battery is discussed in section 2.7. Note: The life expectancy of this type of battery will vary depending on several factors such as ambient temperature, and number of deep discharges. Typical life expectancy is 18-24 months. If you decide to mount the battery in an external battery box, the charger should be located in the box with the battery so that it will be at the same temperature as the battery. You may use the Kimray KA7369 charger in the box instead of mounted on the K500 Main Electronics Card and connect the Power output terminal of the charger to the BATT input on the K500 Main Electronics Card (refer to Figure 2-14 Power Control – Charger Terminals) RADIO K500 BATTERY Figure 2-12 Radio and Battery Installation 2.11 Mounting the Solar Panel Solar power allows installation of the K500 in locations where line power is not available. The two important elements in a solar installation are solar panels and batteries. Solar panels and batteries must be properly sized for the application and geographic location to ensure continuous, reliable operation. A 12-volt solar panel can be installed to provide charging power for the backup batteries. The panel can be rated at up to 100 watts and is sized depending upon © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 23 the power requirements of the K500. The solar panel typically mounts to the same 2-inch pipe that supports the K500 ( refer to Figure 2-13 Solar Panel Mounting.) The panel wiring is brought into the K500 enclosure through the prepunched holes in the bottom of the enclosure and is terminated at the charge (CHGR and GND) power terminals on the Charger Card. Refer to section 2.7.1 The panel must face due South (not magnetic South) in the Northern Hemisphere and due North (not magnetic North) in the Southern Hemisphere. The legend of a topographic map will give you the magnetic declination. Magnetic declination is the difference between true north (the axis around which the earth rotates) and magnetic north (the direction the needle of a compass will point). The National Geophysical Data Center has a web page (http://www.ngdc.noaa.gov/seg/geomag/jsp/Declination.jsp) that will calculate your necessary declination adjustments on-line. You will be given the declination adjustment value, in degrees and minutes and whether it is an East or West adjustment. The panel must also be tilted at an angle from horizontal dependent on latitude to maximize the energy output. The angles for different latitudes are normally included in the solar panel documentation. At most latitudes, the performance can be improved by less of an angle during the summer and more of an angle during the winter. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 24 K500 Installation Manual SOLAR PANEL SOLAR PANEL MOUNTING BRACKET Note: Mount the bracket on the other side of the pole if you want to extend the pipe for an antenna U BOLTS SOLAR PANEL CABLE 2” PIPE K500 Figure 2-13 Solar Panel Mounting 2.12 Power This section describes connecting your K500 to a Battery, Radio, Charging Source and other power devices. The power terminal barrier is on the top right of the K500 (refer to the bottom right of Figure 2-3). Figure 2-14 Power and Charger Terminals shows the Terminals on the Charger Card and the K500 Main Electronics Card. Figure 2-15 illustrates the connections. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 25 GND BATT GND GHGR GND OUT DISPLAY PERIPH GND BATT GND AUX 485- 485+ GND SAUX Figure 2-14 Power and Charger Terminals 2.12.1 Description of the Charger Card Terminals A description of the Charger Card connections follows: Battery Input (BATT and GND) The positive terminal of the battery connects to BATT and the minus to GND. Charger Input (CHGR and GND) A 12-volt solar panel is normally used as the charging source for the battery. The positive output of the panel connects to the CHGR terminal and the minus to the GND terminal as shown. The maximum current for the charger on the K500 is 5 A. This limits the maximum size of the solar panel controlled by the K500 to 100 watts. If a larger solar panel is required, an external battery charging regulator must be used. Power Output (OUT and GND) The output of the charger card has a low voltage disconnect. If the battery voltage drops below 11.5 volts the battery is disconnected from the OUT terminal. 2.12.2 Description of the K500 Main Card Power Terminals A description of the K500 Main Card Power connections follows: Battery Input (BATT and GND) The output of the charger Card connects to BATT and the minus to GND. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 26 K500 Installation Manual Auxiliary Output (AUX and GND) The Auxiliary Output provides a battery voltage terminal to power external devices and to supply power for a radio. AUX+ is positive and GND is minus. 2.12.3 Power Interconnections The K500 Cards use compression terminals. Each terminal can accommodate one wire up to 12 AWG in size or 2 wires up to 16 AWG in size. In all cases, connections are made by baring the end (¼ inch maximum) of the wire, inserting the bared end into the clamp beneath the termination screw, and then tightening the screw. The inserted wires should have a minimum of bare wire exposed to prevent short circuits. The connectors provided on the Charger, K500 Main Electronics and RS-232 Communications Cards are Shown below and defined above in Sections 2.8.1 and 2.8.2. KIMRAY RS232 GND BATT GND GHGR GND OUT DISPLAY PERIPH GND BATT GND AUX 485- 485+ GND SAUX PWR IN OUT RADIO + - AUXILLARY + DEVICES - - BATTERY + - SOLAR + PANEL FIGURE 2-15 K500 POWER INTERCONNECTIONS 2.12.4 Connecting Ground Wiring The K500 and related components must be connected to an earth ground. The National Electrical Code (NEC) governs the ground wiring requirements for all line-powered devices. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 27 A ground lug is located inside the enclosure at the bottom left-hand side. This ground provides a terminal to connect shields from I/O wiring, line-power earth ground, and other device earth grounds as required. An external lug on the bottom outside of the enclosure provides a place to connect an earth ground to the enclosure. This ground lug is electrically connected to the internal ground lug through the enclosure. Note: Insure that the ground lug has a star washer against the bare metal of the enclosure, both inside and outside of the enclosure. All earth grounds must have an earth to ground rod or grid impedance of 25 ohms or less as measured with a ground system tester. The grounding conductor should have a resistance of 1 ohm or less between the K500 case ground lug and the earth ground rod or grid. The grounding installation method for the K500 depends on whether the pipeline has cathodic protection. On pipelines with cathodic protection, the K500 must be electrically isolated from the pipeline. The ground installation for pipelines without cathodic protection is shown in Figure 2-16 Ground Installation – Meter Run without cathodic protection. Electrical isolation can be accomplished by using insulating flanges upstream and downstream on the meter run. In this case, the K500 could be flange mounted or saddle-clamp mounted directly on the meter run and grounded with a ground rod or grid system. It is recommended that 14 AWG or larger wire be used for the ground wiring. Make sure the installation has only one ground point to prevent creation of a ground loop circuit. A ground loop circuit could cause erratic operation of the system. The Electronics Boards are electrically isolated from the enclosure; no earth ground connections to the boards should be made. The recommended cable for I/O signal wiring is an insulated, shielded, twisted-pair. The drain shields of I/O signal wiring (such as the RTD cable) should be connected to earth ground at one end only to minimize signal errors caused by Electro-Magnetic Interference (EMI), Radio Frequency Interference (RFI), and transients. Do not connect the earth ground to any terminal on the Main Electronics Board. It could result in property damage. For line-powered installations, the grounding conductor must end at the service disconnect. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 28 K500 Installation Manual HL METER RUN GROUND CONDUCTOR GROUND ROD Figure 2-16 Ground Installation – Meter Run without cathodic protection 2.13 RTD Installation Temperature is a direct input through the Resistance Temperature Detector (RTD) probe and circuitry. An RTD temperature probe mounts directly to the piping using a thermowell outside the K500 enclosure. The thermowell should be located downstream of the orifice fitting so that the average fluid temperature at the plate is measured. The tip of the thermowell should be located within the center third of the inside pipe diameter. RTD wires should be protected either by a metal sheath or by conduit connected to a liquid-tight conduit fitting on the bottom of the enclosure. The RTD wires connect to the four screw terminals designated “RTD” on the Multivariable Interface Board. Refer to Figure 2-17 RTD Wiring Terminal Connections. The K500 provides terminations for a four-wire 100-ohm platinum RTD with a DIN 43760 curve. The RTD should have an alpha equal to 0.00385. A three-wire or two-wire RTD probe can be used instead of a four-wire probe; however, they may produce measurement errors due to signal loss on the wiring. Wiring © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 29 between the RTD probe and the K500 must be shielded wire, with the shield grounded only at the RTU enclosure to prevent ground loops. Ground loops cause RTD input signal errors. During operation, the RTD is read once per second. The value from the RTD is linearized, and then converted to engineering units. The RTD terminals on the Multivariable Interface Board are defined in Table 2-1 Terminal 4-Wire RTD 3-Wire RTD 2-Wire RTD 1 White White Jumper to other 1 term. 1 White White White 2 Red Red Red 2 Red Jumper to other 2 term. Jumper to other 2 term. Table 2-1 RTD Input Wiring 485485+ GND 1 1 2 RTD 2 V+ NOTE: CONNECT RTD SHIELD TO K500 GROUND LUG RED RTD WHITE Figure 2-17 RTD Wiring Terminal Connections Note: Remove power from the K500 before performing any field wiring © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 30 K500 Installation Manual Adjust probe length so that it is spring loaded against the bottom of the thermowell. Remove nut from water tight cord connector. On the K500 insert wires through the hole. Allow enough RTD cable to extend into the K500 for connecting wires to the RTD terminal Block (Figure 2-17). Secure RTD Probe cable using supplied sealing ring and nut. Connect RTD probe to the K500 RTD terminal block as follows: Loosen terminal block securing screws, insert wire then retighten. Following connection of RTD into the thermowell, secure cable to meter run pipe with UV resistant plastic tie wraps. Do not wrap cable around meter run pipe. 2.14 Connecting Your Computer To perform initial setup or calibration you can temporarily connect your computer to the K500. If your K500 was ordered with an LOS (Local Operator Station) Jack, then you can connect to the outside of the enclosure with an LOS cable (you can order the cable from Kimray, KA3920). The LOS jack is located on the left side of the enclosure (Refer to Figure 2-18 LOS Jack). LOS JACK Figure 2-18 LOS Jack One end of the cable connects to your computer and the other end to the K500. Each end has a removable DB-9 connector. When you are connecting to the © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 31 external LOS jack, remove the DB-9 connector and plug the RJ-11 cable directly into the jack. If you do not have an external LOS jack, you can connect directly to the PERIPH port on the K500 main board with the RJ-11 cable (Refer to Figure 219 PERIPH Port, Figure 2-20 K500 LOS Cable Wiring and Figure 2-21 K500 LOS JACK Wiring Diagram). PERIPH (LOS) PERIPH Kimray K500 DISPLAY LITHIUM BATTERY FLAS H MAIN ELECTRONICS CARD ENCLOSURE DOOR (Inside) or BACKPANEL Figure 2-19 PERIPH Port K500 Male 4-pin RJ11 Connector COMPUTER Female DB9 Connector TXD 1 2 RXD (Received Data) RXD 3 3 TXD (Transmitted Data 4 DTR (Data Terminal Ready) GND 4 5 GND (Common) 8 CTS (Clear to Send) Figure 2-20 K500 LOS Cable Wiring Diagram © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 32 K500 Installation Manual 12345678 LOS JACK (Female RJ45Connector) K500 Female RJ45 Connector LOS JACK Female RJ45 Connector TXD 3 3 TXD (Received Data) RXD 5 5 RXD (Transmitted Data GND 6 6 GND (Common) Figure 2-21 K500 LOS JACK Wiring Diagram © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 33 3 Inputs and Outputs Introduction This section describes the Inputs and Outputs (I/O). 3.1 Description The K500 has an optional Discrete (Digital) Input/Output (DIO) card, an Analog Input card, external I/O CIMs and can connect to an internally mounted multivariable sensor (MVS) or external multivariable sensors for measuring pressures and temperatures. The K500-series Input/Output (I/O) cards, shown in Figure 3-1 K500 ANALOG INPUT CONNECTIONS, Figure 3-2 K500 Digital and Accumulator Input Connections, and Figure 2-3 K500 Layout, provide additional inputs and outputs for expanded monitoring and control applications. The I/O channels have terminal blocks for field wiring. In addition, the Discrete (Digital) I/O card has eight LEDs (Light Emitting Diodes) to indicate the state of the Discrete Inputs, Discrete Outputs, and Pulse Input. 3.2 Discrete (Digital) I/O Card The Discrete (Digital) I/O Card (DIO) is available in two versions. One version (KA7214) utilizes relays and the other (KA7331) has solid state switches. The DIO has 4 discrete (status) inputs. Each input is differentially surge protected with Metal-Oxide-Varistors and is designed to pass IEEE 472-1974. The input pull-up current for dry contacts is supplied from the K500 internal power. When the plus input is connected to its minus input, a current flows providing a signal read by the input circuitry and turning on the LED for the channel. The DIO also has a high-speed accumulator (pulse) input channel. It is differentially surge protected with Metal-Oxide-Varistors and designed to pass IEEE 472-1974. The operating speed of the input circuitry is 25 kHz minimum when no filtering is selected. Two jumpers are available to select filtering for input frequencies of 1 kHz or 30 Hz. The DIO provides 3 discrete output channels. With the relay version two of the channels are SPDT (Form C) relays with a 10 A rating. Each channel provides both normally open (NO) and normally closed (NC) contacts. The version without relays provides solid state switches for two of the channels. The third output on both versions is an open collector transistor that electrically switches the input line to ground © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 34 3.3 K500 Installation Manual Analog Input Card The K500 has 2 optional external analog input channels configurable for a range of 1 to 5 Volts or 4 to 20 mA. The K500 also measures one internal signal which is battery voltage. All inputs are measured by a successive approximation analog-to-digital converter with 12 bits of resolution. The analog section references a precision temperature compensated voltage reference. Each of the two external high-level analog inputs is protected by a gas filled surge arrester. Additional protection for the input circuitry is provided by a filter resistor and capacitor for each channel. Each external high-level channel is provided with a 250 resistor for use with 4 to 20 mA inputs. Closing the jumper for the channel enables the resistor. The resistor converts the 4 to 20 mA current into a 1 to 5V signal. 20 volt power with enough current to support two current loops is optionally available on the Power Control – Charger Card (refer to Figure 2-10 K500 POWER INTERCONNECTIONS AND FUSING) 3.4 Installing an I/O Card The I/O Cards install on the door of the K500 enclosure or on a backplane with the steel enclosure with no display. The I/O Cards electrically connect to the Main Electronics Board with mating connectors. Each of the I/O Cards physically mount on two standoffs and secure with two #4-40 screws. Refer to Figure 2-2, K500 Layout 1. Use appropriate electrostatic discharge precautions, such as wearing a grounded wrist strap to avoid circuit damage when working with the K500. 2. Always turn the power to the K500 off before you attempt any type of wiring by unplugging the Power terminal block on the Power Control – Charger Card. 3. Mate the 20-pin connector on the Discrete (Digital) I/O Card with the connector on the Main Electronics Board or mate the 4-pin connector on the Analog Input Card with the connector on the Main Electronics Board. 4. After mating the connectors, press firmly to seat the board and ensure that the card is over the two standoffs. 5. Install two #4 - 40 screws. 6. Apply power - Plug in the Power terminal block on the Power Control – Charger Card to restore power to the K500 © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 3.5 Page 35 I/O Wiring The field terminals on the K500 I/O Cards are connected as explained in the following sections. I/O wiring requirements are site and application dependent. Local, state, or NEC requirements determine the I/O wiring installation methods. Direct burial cable, conduit and cable, or overhead cables are options for I/O wiring installations. The I/O Cards containing the field wiring terminal connections are accessed by opening the front door after removing the lock (if installed) and releasing the hasps on the right-hand side. The input terminal wiring is arranged on the lower edge of each of the I/O Cards. The terminal designations are printed on the circuit board. 3.5.1 Analog Inputs Analog Inputs (AIs) monitor current loop and voltage input devices. The A/D converter signal input range is from 1 to 5 volts. The Analog Inputs have two field terminals per channel. A 250-ohm scaling resistor is supplied for use between the “+” and “-” Analog Input terminals and is enabled by inserting a jumper for the appropriate cannel. The “+” terminal is the positive signal input and the “-” terminal is the signal common. These terminals accept a voltage signal in the 1 to 5 volt range. Because the “-” terminal is internally connected to common, the Analog Input channels function as single-ended inputs. When connecting the Analog Input channel to a voltage device, be sure to remove the 250-ohm resistor jumper from the Analog Input card. Figure 3-2 K500 Digital and Accumulator Input Connections shows wiring for a 2-wire current or 3-wire voltage transmitter TO AUX POWER Optional Analog Input card JP1 1+ 1- Jumpers to connect 250 Ohm resistors for current loop inputs JP2 20 V. POWER SUPPLY 0+ 0- KIMRAY C ANALOG INUTS V FIGURE 3-1 K500 ANALOG INPUT CONNECTIONS © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 36 K500 Installation Manual 3.5.2 Discrete Inputs Discrete Inputs (DIs) monitor the status of relays, solid-state switches, or other two-state devices. DI functions support discrete latched inputs and discrete status inputs. An LED is included for each point to indicate the state of the input. The Discrete Input operates by providing a voltage across terminals “DI” and “GND” (Figure 3-2 K500 Digital and Accumulator Input Connections), which is derived from internal voltage source. When a field device, such as a relay contact is connected across “DI” and “GND,” the closing of the contacts completes the circuit which causes a flow of current. This current flow turns on the LED and is sensed in the DI circuitry that, in turn, signals the K500 electronics indicating that the relay or switch contacts have closed. When the contacts open, current flow is interrupted and the DI circuit signals to the K500 electronics that the contacts have opened and the LED is turned off. Optional Digital I/O card with Relays KA7214 TB1 TB1 JP1 JP2 ONC ONO OCOM V+ ACC+ ACC- Power from D500 Power Card Aux Terminal 1COM JP1 JP2 GND AUX PWR GND KIMRAY KIMRAY V+ ACC+ ACCGND Optional Digital I/O card without Relays KA7331 0OUT 1OUT 1NO GND 1NC PWR2 2COL 2OC DI0 GND DI1 DI0 DI2 DI1 DI3 GND DI2 DI3 TB2 TB2 FIGURE 3-2 K500 Digital and Accumulator Input Connections 3.5.3 Discrete (Digital) Outputs There are two versions of the K500 Discrete (Digital) I/O Card, a Relay version (KA7214) and a solid state switch (KA7331) version. Each version has 3 discrete (digital) output channels. Discrete Outputs (DO) on the I/O Card provide switches to control relays and power small electrical loads such as motors and pumps. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 37 Relay Version Two of the Discrete (digital) output channels are form C contacts (SPDT). The outputs of the relays are available on the terminal barrier along the edge of the K500 Discrete (Digital) I/O card (Figure 3-2). Each of the relay channels has three screw terminals: COM, NO and NC. The COM terminal is the pole of the relay, NO is the normally open contact and NC the normally closed contact. Each relay has an LED to indicate when the channel is energized. The terminal labeled 2COL is the open collector output channel used to electrically connect its input to ground. Figure 3-3 2COL Channel Connection – Relay Version illustrates the connection of a solenoid valve to this channel. The diode should be connected at the solenoid. Note the connection of a diode across the coil of the solenoid (refer to Appendix C) Battery Voltage comes from the AUX+ terminal of the Power Card (refer to section 2.7.1). BATTERY VOLTAGE TO AUX+ DIODE 1N4000 TB2 LED IRLD024 1 2 3 4 5 6 7 8 9 10 11 12 O O O O O O O O O O O O 0NC 0NO 0COM 1COM 1NO 1NC 2COL DI0 DI1 DI2 DI3 GND SOLENOID DIGITAL I/O CARD FIGURE 3-3 2COL Channel Connection – Relay Version Solid State Switch Version Two of the discrete (digital) output channels are a set of solid state switches. The switches on either channel normally connect the output to ground. When the output is activated (equivalent to closing the relay switch) the output is switched to the Aux Power Input Voltage. The outputs of these two channels are available on the terminal barrier along the edge of the K500 Discrete (Digital) I/O card (Figure 3-2). Each of the channels has one screw terminal: the channels are labeled 0OUT and 1OUT. Each channel has an LED to indicate when the channel © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 38 K500 Installation Manual is energized. Figure 3-4 illustrates the connection of a Kimray EPC to these channels. The switches shown are solid state switches. 1 2 3 4 5 6 7 8 9 10 11 12 TB2 O AUXPWR O GND O 0OUT O 1OUT O GND O PWR2 O 2OC O GND O O O O TO AUX POWER EPC (or Mag Latch Solenoid) DIGITAL I/O CARD FIGURE 3-4 Channel 0OUT and 1OUT Connection The terminal labeled 2COL is the open collector output channel used to electrically connect its input to ground. Figure 3-5 illustrates the connection of a solenoid valve to this channel. Note the connection of a diode across the coil of the solenoid (refer to Appendix C). The diode should be connected at the solenoid. The other side of the solenoid should be tied to the PWR2 Terminal. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual BATTERY VOLTAGE Page 39 TO AUX PWR DIODE TB2 LED 1 2 3 4 5 6 7 8 9 10 11 12 O O O O O O O O O O O O AUXPWR GND 0OUT 1OUT GND PWR2 2OC SOLENOID DIGITAL I/O CARD FIGURE 3-5 2COL Channel Connection – Solid State Switch Version 3.5.4 Pulse (Accumulator) Input Pulse Inputs (PIs) count pulses from pulse-generating devices. The Pulse Input routes to a pulse accumulator, where the pulses are counted and accumulated. The Pulse (accumulator) input terminates in the four compression screws of the Accumulator terminal strip (refer to Figure 3-2 K500 Digital and Accumulator Input Connections). The terminals are: V+, ACC+, ACC- and GND. An LED monitors the input state. JP1 Jumpers JP1 and JP2 select the frequency response of the Accumulator. When no jumpers are used there is no filtering of the input. Jumper JP2 enables 1 KHz low pass filtering, jumper JP1 enables the 30 Hz low pass filter. JP2 No Filtering JP1 JP2 1 KHz Filtering JP1 Some devices generate or switch ON a voltage when they JP2 change state (voltage input devices). Some devices only 30 Hz Filtering close a contact when the state is changed. The Accumulator input interface senses the change of state of both types of devices. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 40 K500 Installation Manual Contact Input Devices The K500 powers the contact closure inputs. V+ connects to ACC+ and the switch (or open collector transistor) connects between ACC- and GND, as illustrated in Figure 3-2 K500 Digital and Accumulator Input Connections. When the field device completes the circuit between “ACC-” and “GND” terminals, the indicator LED lights to show an active circuit, and the input circuitry is triggered, producing a signal to the K500. Voltage Input Devices The most common type of voltage input device is the relay or switch. When open, there is no power on the switched side of the device. When the relay is energized or the switch is closed, there is power on the switched side of the device. Wiring from the switched side of the device and a power return provides the required sensing signal. For this case the input connects between ACC+ and ACC- and the V+ terminal is not used. The Pulse Input can operate at up to 25 kHz, with a maximum 50% duty cycle. 3.5.5 LED’s Eight LED indicators are located on the Discrete (Digital) I/O Card. When a specific PI (1), DI (4), or DO (3) is active, then the corresponding LED lights. Refer to Figure 3-2 K500 Digital and Accumulator Input Connections. 3.6 K500 Multivariable Sensor This section describes the K500 Multivariable Sensor (MVS). The MVS provides differential pressure and static pressure inputs to the K500 for orifice flow calculations. The MVS Sensor assembly also provides a temperature input to the K500 by means of an RTD input. 3.6.1 Description of Sensors The MVS measures differential pressure and absolute static pressure by converting the applied pressure to electrical signals and making the readings available to the Main Electronics Card. Internally Mounted MVS The Internally Mounted MVS housing mounts with four bolts to the bottom of the K500 enclosure. The MVS interface card mounts inside the K500 on a bracket which is also secured by the four mounting bolts or on the backpanel on the no display version. The MVS interface card is connected to the K500 Main Electronics Card with RS-485 cabling (refer to Section 2.7.4). Externally Mounted MVS The Externally Mounted MV sensors are in explosion proof red housings and can be mounted close to the pressure taps on the meter run. Up to 4 MVS sensors may be connected to the K500 ( including the internal MVS if it is used). The MVS is connected to the K500 Main Electronics Card with RS-485 cabling (refer to Section 2.7.4). © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 3.6.2 Page 41 Process Connections Piping from the meter run connects to the MVS of the K500. Both the static and differential pressures pipe to female ¼-18 NPT connections on the bottom of the MV. (refer to Figure 2-5 K500 Mounting and Connections). The K500 is an upstream device, meaning that the static pressure line connects to the high pressure side (labeled “H” on the sensor body) and upstream values are calculated. 3.6.3 Sensor Wiring If you order the internal MVS, theK500 and the MVS ship from the factory with the wiring connected between them. Always turn off power to the K500 before you connect or disconnect wiring. Wiring of powered equipment could result in property damage. 3.7 K500 Turbine Meter Input The DACC50 provides for the measurement of the flow of natural gas or water using turbine metering. The Optional DIO card provides terminals for a pulse counter (PI) input from a turbine meter (refer to 3.5.4 Pulse (accumulator) Input). The K500 can count pulses acquired from a turbine meter and use them to determine an instantaneous flow rate. The accumulated input pulses are totalized and stored in history. Kimray provides optional Turbine Meter Interface Cards (pre-amps) to provide gain for low-level turbine signals. One version of the Card plugs directly onto the terminal strip and receives its power from the K500 (refer to Figure 3-6 Turbine Meter Interface). The turbine meter connects to the “SIGNAL” and “GND” input terminals. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 42 K500 Installation Manual TB1 V+ TO TURBINE PULSE AMPLIFIER ACC+ SIGNAL ACC GNDGND ONC ONO OCOM 1COM 1NO 1NC 2COL DI0 DI1 DI2 DI3 GND TB2 Figure 3-6 Turbine Meter Interface © 2006 Kimray, Inc. (ENG-017 Rev. 1) DIO CARD K500 Installation Manual Page 43 4 Calibration Introduction This section describes calibrating the K500. The calibration mode allows you to calibrate, check and zero the multivariable static and differential pressure and flowing temperature Resistance Temperature Detector (RTD) as well as the two analog inputs . Required Test Equipment The following test equipment is required to calibrate the K500 : Computer with IMI software program or a terminal program such as the Kimray VbTerm (refer to paragraph 2.10 Connecting Your Computer). Deadweight tester or equivalent calibration standard. Test Gauge capable of dual range measurement (PSIG and Inches). Barometer or another means which can determine barometric pressure. Nitrogen or compressed air source. RTD simulator. Meter Maintenance Mode When calibrating the flow computer inputs the K500 must be instructed to ignore live values for flow calculations while the K500 is being calibrated. Refer to Chapter 6, Meter Maintenance Mode. This prevents real time K500 flow calculations and control from being affected during the calibration. Absolute Pressure Measurement The K500 multivariable uses an absolute pressure Static Pressure transducer. Absolute pressure measures the pressure referenced to a vacuum instead of gauge pressure which is referenced to the atmosphere. The K500 allows you to enter a value for atmospheric pressure which it will then use during calibration to allow you to work in gauge pressure. Kimray recommends entering the current barometric pressure into the K500 before calibration. The K500 then automatically subtracts this value from the value of the absolute pressure reading. The absolute pressure can be entered in the Calibration Mode in the CALIBRATE ANALOG INPUT sub menu (refer to paragraph 4.1). If you do not have an accurate barometer, it is recommended that you enter 0 for Atmospheric Pressure and make the initial calibration point be at vented conditions. The current pressure reading is then a good value for the barometric pressure since the static pressure sensor is measuring the true pressure relative to a vacuum and, when vented, this is the barometric pressure. You can now enter this reading as the new atmospheric pressure value and proceed with your calibration. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 44 4.1 K500 Installation Manual Calibrating Static Pressure A two or three point pressure method is used to calibrate the K500 Static Pressure cell. These different pressures are applied to the cell from a known traceable source with resultant pressure values entered into the K500. The K500 uses an absolute Static Pressure (SP) sensor. Absolute pressure measures the pressure referenced to a vacuum as opposed to a gauge sensor which measures the pressure referenced to the atmosphere. For all points of calibration, the K500 subtracts the value you have entered for Atmospheric pressure from the static pressure reading so that you can work in gauge pressure (the K500 is still using absolute pressure for its flow calculations). During normal operation of the K500, the display provides continuous SP readouts. However during calibration the K500 is placed in Meter Maintenance Mode, which is a temporary hold mode (see Chapter 6). The K500 allows you to check the Static Pressure Calibration by logging the pressure marker check points during calibration. These marker points are logged by answering Y to the question “Write Values to Event Log?” It is recommended that checks of the Static Pressure (SP) be during and directly following the calibration. Figure 4-1 Event Log Example shows an example of a portion of the event log. In this log example Marker values were written to the log after each point during calibration of SP and DP. DATE/TIME ----------------06/20/05 12:44:12 06/20/05 12:44:12 06/20/05 12:44:12 06/20/05 12:44:12 06/20/05 12:44:12 06/20/05 11:50:42 06/20/05 11:50:42 06/20/05 11:50:42 06/20/05 11:50:39 06/20/05 11:50:19 06/20/05 11:47:19 06/20/05 11:46:46 06/20/05 11:46:46 06/20/05 11:46:46 06/20/05 11:46:40 06/20/05 11:46:20 06/20/05 11:44:25 06/20/05 11:43:53 CONT DAY/HR ----------06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 06/20/05 00 EVENT DESCRIPTION OLD NEW FC L --------------------- -- Temp exit Maint 99.7 99.75 0 Y SP exit Maint mode 1000 999.9999 0 Y C' exit Maint mode 145.7564 145.7457 0 Y DP exit Maint mode 150 150 0 Y Volume exit Maint 11414 11471.16 0 Y Calib SP, high 1000 1000 0 Y Calib SP, mid 500 500 0 Y Calib SP, low 0 0 0 Y Marker SP 1000 1000 0 Y Marker SP 500.4995 500 0 Y Marker SP 3.26e-8 0 0 Y Calib DP, high 150 150 0 Y Calib DP, mid 75 75 0 Y Calib DP, low 0 0 0 Y Marker DP 150 150 0 Y Marker DP 74.10114 75 0 Y Marker DP 0.0373223 0 0 Y Enter Maint Mode 0 0 0 Y ID IDX -- --1 33 1 32 1 31 1 30 1 29 1 28 1 27 1 26 1 25 1 24 1 23 1 22 1 21 1 20 1 19 1 18 1 17 1 16 Figure 4-1 Event Log Example You can enter as many SP pressure markers as you desire but recording too many markers can cause the K500 to overwrite existing older events so it is recommended to just enter low, mid and high values. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 45 During the Calibrate Static Pressure procedure, you will pressure both sides of the sensor by going from the normal operational position of the 3-valve manifold shown below, through the following five steps. H L MANIFOLD VENT VENT CLOSED OPEN OPEN Normal Operation You will pressure both sides of the sensor by: 1 Closing the low side orifice block valve, and 2 opening the bypass (equalize) valve. H L H L MANIFOLD MANIFOLD VENT VENT CLOSED OPEN CLOSED 1. Close the block valve to the low (downstream) side. VENT VENT OPEN CLOSED OPEN 2. Open the center bypass valve to equalize the pressure on both sides. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 46 K500 Installation Manual Next, 3 Close the high side block valve and then 4 Open the vents to atmosphere. Now, 5 Close the atmosphere vent and apply pressure to the high side vent. H L H L H L Test Pressure VENT VENT VENT VENT VENT VENT OPEN OPEN OPEN CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED MANIFOLD MANIFOLD 3. Close the upstream block valve 4. Open the vents to atmosphere MANIFOLD 5. Close low side vent and input test pressure to high pressure side vent Note: the vents can be vents on the manifold or the vents on the Multivariable itself Important: While the MVS is pressured to a high test pressure, block the pressure source. Now check the differential pressure. It should remain at 0 ±0.1%. If it is not zero, check for pressure leaks in the system. 4.2 Calibrating Differential Pressure (DP) As discussed above under “Checking Static Pressure (SP) Calibration”, it is recommended that checks of the Differential Pressure (DP) be done prior to and directly following calibration. A two or three point pressure method is used to calibrate the K500 Differential Pressure sensor. These different pressures are applied to the sensor from a known traceable source with resultant pressure values entered into the K500. During normal operation of the K500, the display provides continuous DP readouts. However during calibration the K500 is placed in Meter Maintenance Mode, which is a temporary hold mode (refer to Chapter 6). The K500 allows you to check the Differential Pressure Calibration by logging the pressure marker check points during calibration. These marker points are logged by answering Y to the question “Write Values to Event Log?” It is recommended that checks of the Differential Pressure (SP) be during and directly following the calibration. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 47 You can enter as many DP pressure markers as you desire but recording too many markers could cause the K500 to overwrite existing older events so it is recommended to enter a low, mid and high values. During the Calibrate Differential Pressure procedure, you will zero the pressure sensor by going through the following 4 steps. H L MANIFOLD VENT VENT CLOSED OPEN OPEN Normal Operation © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 48 K500 Installation Manual You will zero the pressure sensor by: 1 Closing the low side orifice block valve and 2 opening the bypass valve. H L H L MANIFOLD MANIFOLD VENT VENT VENT VENT OPEN CLOSED CLOSED OPEN CLOSED OPEN 1. Close the block valve to the low (downstream) side. 2. Open the center bypass valve to equalize the pressure on both sides. Next, 3 close the upstream (high) side block valve and 4 open the vents to atmosphere: H L H L VENT VENT VENT VENT OPEN CLOSED OPEN CLOSED CLOSED CLOSED MANIFOLD 3. Close the upstream block valve MANIFOLD 4. Open the vents to atmosphere (zeroing) This gives you zero pressure across the pressure sensor. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 49 Now to apply pressure to the sensor: 5 Close the bypass valve and apply pressure to the high side vent. H L Test Pressure VENT VENT CLOSED CLOSED CLOSED MANIFOLD 5. Close the bypass valve and Input test pressure to high pressure side vent 4.3 Returning the Multivariable to service To return the sensors to serve you will: 1 Open the bypass (equalize) valve, 2 Close the vents and then 3 Open the upstream (high) side block valve H L H L H L MANIFOLD MANIFOLD VENT VENT VENT VENT VENT VENT OPEN OPEN OPEN CLOSED CLOSED CLOSED CLOSED CLOSED OPEN MANIFOLD 1. Open the bypass valve if it is closed 2. Close the vents. © 2006 Kimray, Inc. (ENG-017 Rev. 1) 3. Open the upstream block valve. Page 50 K500 Installation Manual Next, 4 Open the downstream (low) side block valve and 5 close the bypass (equalize) valve. H L MANIFOLD VENT VENT CLOSED OPEN 4. Open the downstream block valve 4.4 OPEN 5. Close bypass valve. Now back to normal operation Using a Five Valve Power Pattern Manifold The schematic for a 5-valve power pattern manifold is shown in the figure below (refer to section 4.5 for gas pattern manifolds: This manifold is similar to the 3valve manifold in that it has two line block valves and an bypass (equalize) valve. The other two valves are vent valves for calibration. H L TEST/ VENT CLOSED VENT CLOSED OPEN CLOSED OPEN 5-Valve Power Pattern Manifold, Normal Operation The operation of the valve for calibration is the same as for the 3-valve, except that you for each step that you open or close a vent, you now simply open or © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 51 close the appropriate vent valve. When applying a pressure, connect your test pressure to the test valve and use the vent valve to vent the transmitter. 4.5 Using a Five Valve Gas Pattern Manifold The 5-valve gas pattern has two has two line block valves, two bypass (equalize) valves and a vent valve. The operation of the valve is illustrated below. 4.5.1 Calibrating Static Pressure (SP) During the Calibrate Static Pressure procedure, you will pressure both sides of the sensor by going from the normal operational position of the 5-valve manifold shown below, through the following five steps. H L VENT VENT CLOSED CLOSED OPEN OPEN OPEN Normal Operation You will pressure both sides of the sensor by: 1 Closing the low side orifice block valve and the vent valve, and 2 opening the bypass (equalize) valves. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 52 K500 Installation Manual H L H L VENT VENT CLOSED VENT VENT OPEN CLOSED OPEN OPEN OPEN CLOSED CLOSED CLOSED 1. Close the block valve to the low (downstream) side and the vent valve. CLOSED 2. Open the center bypass valves to equalize the pressure on both sides. Next, 3 Close the high side block valve and then 4 Open the vent to atmosphere. Now, 5 Close the atmosphere vent valve and apply pressure to the high side vent. H L H L H L Test Pressure VENT VENT VENT OPEN VENT VENT OPEN OPEN CLOSED VENT OPEN OPEN CLOSED OPEN CLOSED OPEN CLOSED CLOSED 3. Close the upstream block valve CLOSED 4. Open the vent to atmosphere CLOSED 5. Close vent and input test pressure to high pressure side vent Note: the vent for the test pressure can be a vent on the manifold or a vent on the Multivariable itself Important: While the MVS is pressured to a high test pressure, block the pressure source. Now check the differential pressure. It should remain at 0 ±0.1%. If it is not zero, check for pressure leaks in the system. © 2006 Kimray, Inc. (ENG-017 Rev. 1) CLOSED K500 Installation Manual 4.5.2 Page 53 Calibrating Differential Pressure (DP) During the Calibrate Differential Pressure procedure, you will zero the pressure sensor by going through the following 4 steps. H L VENT VENT CLOSED CLOSED OPEN OPEN OPEN Normal Operation You will zero the pressure sensor by: 1 Closing the low side orifice block valve and 2 opening the bypass valve. H L H L VENT VENT CLOSED OPEN CLOSED OPEN OPEN OPEN CLOSED VENT VENT CLOSED 1. Close the block valve to the low (downstream) side and the vent valve. CLOSED CLOSED 2. Open the center bypass valves to equalize the pressure on both sides. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 54 K500 Installation Manual Next, 3 close the upstream (high) side block valve and 4 open the vent to atmosphere: H L H L VENT VENT VENT VENT OPEN OPEN OPEN CLOSED OPEN CLOSED OPEN CLOSED CLOSED 3. Close the upstream block valve CLOSED 4. Open the vent to atmosphere (zeroing) This gives you zero pressure across the pressure sensor. Now to apply pressure to the sensor: 5 Close the high side bypass valve and apply pressure to the high side vent. H L Test Pressure VENT VENT CLOSED CLOSED OPEN CLOSED 5. Close the bypass valve and Input test pressure to high pressure side vent © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 4.5.3 Page 55 Returning the Multivariable to service To return the sensors to serve you will: 1 Open the bypass (equalize) valve, 2 Close the vents and then 3 Open the upstream (high) side block valve H L H L H L VENT VENT VENT VENT OPEN OPEN OPEN OPEN VENT VENT OPEN OPEN CLOSED CLOSED OPEN OPEN 1. Open the bypass valves if they are closed CLOSED CLOSED CLOSED 2. Close the vents. CLOSED CLOSED 3. Open the upstream block valve. Next, 4 Open the downstream (low) side block valve, 5 close the bypass (equalize) valves and 6 open the vent valve. H L H L H L VENT VENT OPEN VENT VENT CLOSED OPEN OPEN OPEN CLOSED 4. Open the downstream block valve CLOSED OPEN CLOSED VENT VENT CLOSED CLOSED OPEN OPEN 5. Close bypass valves OPEN OPEN 6. Open the vent valve. Now back to normal operation © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 56 4.6 K500 Installation Manual Calibrating Flowing Temperature (RTD) The following steps describe how to calibrate the RTD input channel (Refer to paragraph 4.8 Temperature Calibration Example.) This procedure requires a device to simulate resistance. The device should be a resistance decade box with 0.01 ohm steps or individual resistors enclosed in a protective enclosure with an accuracy of ±0.2% over the ambient temperature range at the calibration location. 1. Connect the resistor simulator in place of the RTD on the Multivariable Interface Board as shown in Figure 2-12 RTD Wiring Terminal Connections. 2. Set the resistor simulator to the 32º F (0º C) resistance value of 93.03 Ohms. 3. Enter the value of 0 for Low Reading 4. Set the resistor simulator to the 200° F resistance value of 135.97 Ohms. 5. Enter the value of 200 for High Reading. 6. Disconnect the resistor simulator and reattach the RTD probe wiring. After a two point calibration has been done, subsequent calibrations can be single point calibrations. 4.7 Zeroing Input During the process of setting pressure markers to determine the need for a calibration of either the Static Pressure (SP) or the Differential Pressure (DP), you may conclude that the SP or the DP pressures are out of alignment exactly the same amount at each pressure marker (linear shift). When this occurs, you may either perform a complete recalibration of the K500 or you may recalibrate a single point. (This option is only available after the transducer has been previously calibrated). 4.8 Calibration Menus To go into Calibration, select: display screen shown below: 2] Meter Maintenance from the main menu MAIN MENU – 07/28.05 06:43 - KIMRAY 1] Data Display 2] Meter Maintenance 3] Edit Configuration Enter selection> Main Menu This menu selection requires a LEVEL 1 or LEVEL 2 password and takes you to the Meter Maintenance Sub Menu. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 57 METER MAINTENANCE 1] Maint Mode 5] Calibrate 2] Orifice/VC Size6] System TIme 3] Gas Analysis 7] Command DO 4] PROcontrol Enter selection> Meter Maintenance Sub Menu The Meter Maintenance menu shown above allows you to select: [5] Calibrate. Taking you to the Calibrate sub menu shown below. This sub menu allows you to select to calibrate only the AGA sensor inputs or any analog input. CALIBRATE ANALOG INPUT 1. Calibrate AGA Sensors 2. Calibrate Analog Inputs 3. Enter Atmospheric Pressure Enter selection> Calibrate Sub Menu Entering Atmospheric Pressure The choice 3, Enter Atmospheric Pressure from the Calibrate Sub Menu allows you to change the atmospheric pressure being used by the flow computer without having to edit the flow computer directly. Enter Atmospheric Pressure FC 1] 0 FC0 2] 1 FC1 Enter selection> MODE Initialized Not Initial Selecting a Flow Computer causes the following screen to appear, allowing you to enter the barometric pressure in psia: Absolute atmospheric press (psia) <14.7> Calibrating a Sensor If you choose 1. Calibrate AGA Sensors from the Calibrate Sub Menu, you can pick the input to calibrate by picking a flow computer and then choosing one of the sensors associated with that flow computer. If you choose 2. Calibrate Analog Sensors, you pick the sensor to calibrate from a list of all available analog inputs. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 58 K500 Installation Manual Calibrate AGA Sensors Calibrate Analog Sensors Choose the flow computer to calibrate. Choose the analog input to calibrate. CALIBRATE AGA SENSORS FC MODE 1] 0 Well Gas 0 Initialized 2] 1 Not Initial Enter selection> Next, select the sensor to calibrate CALIBRATE ANALOG INPUT AN *** LABEL 1] 00 01C FC 0 Diff Press 2] 01 01C FC 0 Static Pre 3] 02 01C Flow Temp 4] 03 00L Casing Press 5] 04 01L Tubing Press 6] 05 02L Battery Voltage in H2O PSIA deg F PSIG PSIG Volts Enter Input to Calibrate> CALIBRATE AGA SENSORS 1. DP 2. Static Pressure 3. Flowing Temperature Enter selection> Now select the sensor you wish to calibrate. Note that at this point if the input that you are calibrating is associated with a flow computer and if the flow computer is not already in maintenance mode, the K500 will prompt you to put it in maintenance mode with the following screen. Put Flow Computer 0 in maintenance? (Y/N)<Y> Enter timeout (hours)(0.1-3)<1> You will now see one of the following screens allowing you to select the type of calibration you wish to use. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 02 01 Flow Temp 29.14 deg F 1] Use 2 point calibration Page 59 Used for K500 Flowing Temperature input Enter selection> 00 01 Diff Pres 75.0 in H2O 1] Use 2 point calibration 2] USING 3 point calibration Used for K500 Static Pressure and Differential Pressure Enter selection> 03 00 Casing Pres 943.38 PSIG Used for other analog Inputs 1] Use Default Range and Offset 2] Use 2 point calibration 3] USING 3 point calibration Enter selection> Calibration Methods Default Range and Offset - This selection resets the calibration to use the range and offset entered in the Edit Analogs. This is a straight line approximation based on the offset that was entered in the analog software record and the offset + range as span. 2 or 3 Point Calibration - 2 Point Calibration uses two points, a LOW point and a HIGH point. For 3 Point Calibration you can select from LOW, MID, and HIGH points. Resetting Calibration If you have calibrated a sensor attached to either of the two optional analog inputs and in the past and have changed that sensor to one with a different range, then take the following steps to change the range and offset of the sensor. 1. Edit the analog software record associated with the particular input channel to which the sensor is connected. To do this go to the main menu, and select option number three, Edit Configuration. Then select option 1, Edit I/O, and option 2, Edit Analog Records. Change the offset of the sensor, and the range should change automatically. Once you have done this, return to the “select the type of calibration” menu pictured above. 2. From this menu, select option 1, Use Default Range and Offset. Once this has been done, press the ESC key once, and you are ready to calibrate the sensor. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 60 K500 Installation Manual Calibration Screem Shown below are the Calibration screens for 2 and 3 point calibration. The 2 point screen is the same as the 3 point except only shows LOW and HIGH readings. 00 01 Diff Pres 1] LOW Reading 2] HIGH Reading 2.29 As Found 0.0 0.0 in H2O As Left 0.0 0.0 The calibration screen for 2 point calibration 5]Clear Calibration Enter selection> 00 01 Diff Pres 1] LOW Reading 2] MID Reading 3] HIGH Reading 2.29 As Found 0.0 0.0 0.0 in H2O As Left 0.0 0.0 0.0 The calibration screen for 3 point calibration 5]Clear Calibration Enter selection> Select the reading you wish to calibrate. Readings can be taken in any order and can be recalibrated as many times as necessary; however, the calibration routine will not allow final acceptance of the calibration until each reading has been calibrated the first time the sensor is calibrated. On subsequent calibrations, only one point can be calibrated and accepted. 00 01 Diff Pres 2.29 As Found 1] LOW Reading 2.29 2] MID Reading 0.0 3] HIGH Reading 0.0 Establish LOW Reading Press <ENTER> when ready in H2O As Left 0.0 0.0 0.0 If you choose 1] LOW, the screen changes to this form As you establish a reading the display at the top of the screen shows the value as received by the RTU. Once the reading is established, pressing ENTER sets that reading as the found value. Next enter the actual value which was applied to the transducer. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 00 01 Diff Pres 2.29 As Found 2.29 0.0 0.0 in H2O As Left 0.0 0.0 0.0 1] LOW Reading 2] MID Reading 3] HIGH Reading Enter LOW Reading: -17.71149 – 22.28851<2.288513> Page 61 This screen allows you to enter what the low reading should be and gives the range of acceptable values. Entering 0 for the LOW reading will take you to the following screen. The RTU now displays the transducer reading (as found) with the actual entered value (as left). Entering Y will accept this reading and allow the user to select to write the values to the event log. Entering N returns to Establish Reading 00 01 Diff Pres 1] LOW Reading 2] MID Reading 3] HIGH Reading 2.29 As Found 2.29 0.0 0.0 in H2O As Left 0.0 0.0 0.0 Write Values to Event Log?(Y/N)(N) If you answer Y then a marker will be sent to the event record indicating the old and new values. You will then go back to the original calibration screen to select the MID or HIGH value. You can now select another reading so repeat the above procedures for MID (if 3 point) and HIGH reading. Once all the readings have been calibrated, the RTU will allow the user to accept the calibration. Selecting [4] at this time will make the calibration permanent and write the calibration event to the Event Log. 4.9 Temperature Calibration Example Go into Calibration by selecting 2] Meter Maintenance from the main menu MAIN MENU – 07/28.05 06:43 - KIMRAY 1] Data Display 2] Meter Maintenance 3] Edit Configuration Enter selection> Main Menu This menu selection requires a LEVEL 1 or LEVEL 2 password and takes you to the Meter Maintenance Sub Menu. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 62 K500 Installation Manual METER MAINTENANCE 1] Maint Mode 5] Calibrate 2] Orifice/VC Size6] System TIme 3] Gas Analysis 7] Command DO 4] PROcontrol Enter selection> Meter Maintenance Sub Menu Select 5] Calibrate CALIBRATE ANALOG INPUT 1. Calibrate AGA Sensors 2. Calibrate Analog Inputs 3. Enter Atmospheric Pressure Enter selection> Calibrate Sub Menu Select 1] Calibrate AGA Sensors CALIBRATE AGA SENSORS FC MODE 1] 0 Well Gas O Initialized 2] 1 Not Initial Enter selection> Calibrate AGA Sensors Sub Menu Select 1] FC 0 CALIBRATE AGA SENSORS 1. DP 2. Static Pressure 3. Flowing Temperature Enter Selection> Select 3] Flowing Temperature Put Flow Computer 0 in maintenance? (Y/N)<Y> Enter Y © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 63 Put Flow Computer 0 in maintenance? (Y/N)<Y> Enter timeout (hours)(0.1-3)<1> Put in new value for timeout and hit Enter or just hit Enter for default of 1 hour 02 01 Flow Temp 0.00 deg F 1] USING 2 point calibration Enter Selection> Select 1] 02 01 Flow Temp -0.00 deg F As Found As Left 0.00 0.00 200.00 200.00 1] LOW Reading 2] HIGH Reading 5]Clear Calibration Enter Selection> Select 1] 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading -0.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Establish LOW Reading Press <ENTER> when ready Enter 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading -0.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Enter LOW Reading: (-12.795-9.205)<-1.795> Enter 0 © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 64 K500 Installation Manual 02 01 Flow Temp -0.00 deg F As Found As Left -0.00 0.00 200.00 200.00 1] LOW Reading 2] HIGH Reading Is 0 correct?(Y/N)<N> Enter Y 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading -0.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Write Values to Event Log?(Y/N)<N> Enter Y 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading -0.00 deg F As Found As Left -0.00 0.00 200.00 200.00 4] Accept 5]Clear Calibration Enter Selection> Enter 2] 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading 200.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Establish HIGH Reading Press <ENTER> when ready Enter 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading 200.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Enter HIGH Reading: (186.105-208.105)<197.105> Enter 200 © 2006 Kimray, Inc. (ENG-017 Rev. 1) Note This selection is NOT AVAILABLE until both points have been calibrated the 1ST time calibration is performed K500 Installation Manual 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading 200.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Write Values to Event Log?(Y/N)<N> Enter Y 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading 200.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Is 200 correct?(Y/N)<N> Enter Y 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading 200.00 deg F As Found As Left -0.00 0.00 200.00 200.00 4] Accept 5]Clear Calibration Enter Selection> Enter 4] Accept 02 01 Flow Temp 1] LOW Reading 2] HIGH Reading 200.00 deg F As Found As Left -0.00 0.00 200.00 200.00 Confirm(Y/N)<N> Enter Y, which takes you back to the Calibrate Sub Menu © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 65 Page 66 K500 Installation Manual © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 67 5 RTU Startup This section deals with startup of your K500. 5.1 Initial Startup and Configuration The following screen will appear temporarily if you are connected to the LOS port (refer to paragraph 2.10 Connecting Your Computer) using a terminal program such as VbTerm when the K500 is powered up: K500 SETUP 3:0.6(2,2) -- 12/15/04 Unit 1 Group 0 CAD-UL COMPILER history 2c000 - 7fff0 AUTO CALIB IN USE Last rpoll code = fe9b Press 'Y' to view last message received Strike a key to enter setup If you strike a key while the screen is displayed you will enter into a setup screen, otherwise the following top level menu screen appears: MAIN MENU - 06/28/05 12:27 - KIMRAY 1] Data Display 2] Meter Maintenance 3] Edit Configuration Enter selection > You can check the basic operation of the K500 by selecting 1] Data Display which brings up the following DATA DISPLAY screen: DATA DISPLAY 1] Display AGA 2] Display I/O 3] Reports 4] Prod Hist Enter selection> 5] Comm Viewer 6] EFM History Disp 7] Free RAM Check © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 68 K500 Installation Manual If you next select 2] Display I/O, you will see this menu: Display Software Record Data 1] Summary 2] Detail Enter selection> Selecting 2] Detail lets you choose which software record you want: DISPLAY SOFTWARE RECORD DATA 1] Digital In (4) 2] Analog In (15) 3] Accumulator(4) 4] Digital Out(4) 5] Totalizer (2) Enter selection> Now Selecting 2} Analog In will show you the status of your analog inputs: ANALOG AI *** 00 01C 01 01C 02 01C 03 00L 04 01L 05 02L INPUT RECORD SUMMARY LABEL Diff Press Static Press Flow Temp Casing Press Tubing Press Battery Voltage 2.3 21.0 29.1 944.6 546.5 14.7 in H2O PSIA deg F PSIG PSIG Volts You can see from this display your MVS is readings and your battery voltage as well as the value of any analog inputs. © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 69 6 Meter Maintenance Mode Introduction This section describes the Meter Maintenance Mode of the K500. When a flow computer is put into maintenance mode, the RTU utilizes the current transducer reading at that time to calculate gas flow until the flow computer is returned to normal operation. This function prevents the flow computer from calculating gas flow based on invalid readings taken during calibration. Since the flow computer input values and calculated flow values are frozen while the RTU is in maintenance mode, PROcontrol actions are likewise frozen and no PROcontrol action will take place due to varying calibration signals. While a flow computer is in maintenance mode the Poll Response communication message to the host computer will show that it is in maintenance (in the Flow Computer Status Bit Map). Also events are generated in the K500 event log for the time maintenance mode was entered and for the time that maintenance mode was exited. The K500 Production History record also records entering and leaving maintenance mode When the flow computer is returned to normal operation, the RTU checks to see where the transducer readings are at that time, and corrects the flow rate by computing a straight line from the starting data point to the ending data point. To go into Maintenance Mode, select 1] Meter Maintenance from the main display screen (this menu selection requires a LEVEL 1 or LEVEL 2 password). The Meter Maintenance sub menu shown below will then allow you to select METER MAINTENANCE [1] Maint Mode [6] [2] Orifice/VC Size[7] [3] Gas Analysis [8] [4] PROcontrol [9] [5] Calibrate Enter selection> System Time Command Relays Command Setpoint Enter Event Meter Maintenance Sub Menu [1] Maint Mode. The MAINTENANCE MODE submenu shown below will then allow you to select a flow computer (FC) to put into maintenance mode. Note: a flow computer must be initialized before it can be put into maintenance mode © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 70 K500 Installation Manual MAINTENANCE MODE FC 1] 0 FC 0 2] 1 Enter selection>1 MODE Initialized Not Initial Maintenance Mode Submenu If you then select [1] FC0 for example, you will be asked if you want to enter Maintenance Mode. If you answer Y, you will be asked to enter a timeout. The RTU returns back to normal operation when the maintenance mode timeout expires. This timer insures that the RTU cannot be left permanently in the maintenance mode. The user can manually return the RTU back to the normal operating mode by reselecting maintenance mode, selecting the flow computer that is in maintenance and answering Y to the Exit Maintenance Mode question. After you enter the timeout time, you will be shown a message that you are entering Maintenance mode. FC0 METER 0 /FC 0 Enter Maintenance Mode ?(Y/N)<Y>y Enter maint timeout (hours) (0-8)<1> Entering MAINTENANCE MODE Maintenance Mode entered screen After entering, the following screen will appear showing the flow computer you selected is in Maintenance Mode: You may now select another flow computer to put into Maintenance Mode or ESC to the next higher menu item. Note that if you select a flow computer that is already in Maintenance Mode, you will be asked if you want to exit Maintenance Mode. MAINTENANCE MODE FC 1] 0 FC 0 2] 1 Enter selection> MODE Maintenance Not Initial Maintenance Mode screen Once a Flow Computer is placed into maintenance mode all screens that display the flow computer selection list will indicate the associated flow computer mode as “Maintenance” (below is an example of the Display AGA Screen). © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual DISPLAY AGA DATA FC 1] 0 FC 0 2] 1 Enter selection> Page 71 MODE Maintenance Not Initial Display AGA Data screen Also, if you press <RETURN> at the main menu to remove the password, if there are any flow computers in maintenance mode, the RTU will prompt you to remove them from maintenance mode and return them to normal service. Flow Computer 0 is in maintenance Press ‘Y’ to exit If you do not select “Y”, the RTU will time out, the password will be removed, and associated flow computers will remain in maintenance mode until the timeout occurs. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 72 K500 Installation Manual © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 73 7 Radio Power Cycling and Sleep Operation Introduction This section describes the K500 Radio power cycling and sleep operation. The K500 controls a signal to force a radio into sleep mode and to cycle power on devices that don’t have sleep mode. The K500 controls this signal to keep the radio powered down most of the time to conserve power and to power up periodically to check for a poll. 7.1 Sleep Mode Operation When sleep mode is enabled, the Kimray K500 periodically grounds (with a transistor) pin 9 of its 9-pin communication connector. This pin should be connected to the Sleep or Radio Disable pin (pin 12 of an MDS radio). A ground on this pin totally disables the radio, including transmit, receive, modem and diagnostic functions. Every 5 seconds, the sleep signal is deactivated to allow the radio to wake up. The wake period is set at 450 ms. While the radio is awake, the K500 listens for a message. If the K500 doesn’t receive a message it will go back to sleep. If the K500 does receive a message then it responds to the message and keeps the radio awake for an additional minute to receive any additional messages. Each time a message is received, the 1 minute timer is reset for another minute period. If you communicate with the K500 at least every minute, the K500 will not go to sleep. The sleep and wake time periods are fixed on the K500. 7.1.1 Sleep Mode Setup In the setup menu the question for the RTU Communication operation type shown below allows you to choose Communication operation type 0] Wire line 1] Trunked radio 2] Conventional radio 3] Auto-Dial/Auto-Answer modem 4] Conventional Radio w/ Sleep Mode Enter Selection(0-4)<2>4 4] Conventional Radio w/ Sleep Mode 7.2 Radio Power Switch Mode Operation The Kimray K500 controls a power switching function to cycle radio power for power conservation. A jumper converts the sleep mode function into a power switching function. When the sleep signal is activated and the jumper is installed, the power to the radio is switched off. During the wake period power is switched back on. Figure 2-6 K500 RADIO POWER SWITCH shows the sleep mode/power control circuitry for the K500. The sleep signal is on pin 9 of the COMM port connector. With the jumper installed (JP2), when the sleep signal is 0 volts it will turn off the radio switch, switching off power to the radio. When © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 74 K500 Installation Manual the sleep signal is at 12 volts the radio power switches on. 7.2.1 Daily Power Switch Mode Setup Versions prior to 3:1.0 In the setup menu the question to Daily cycle radio power allows you choose to cycle power. Daily cycle radio power (Y/N)<Y> If you answer Y, you are asked to enter the start time for power cycling Enter time<10:00>10:30 It may take your radio several seconds to power up after its power is turned on. To provide for this you are next asked to enter a radio turn on time: Radio turn on time(secs)(1-60)<1> You are then asked for how long to leave the radio on while waiting for communication. This may be set for a value between 1 and 60 minutes Wait for comm.(min) (1-60)<10> Next, you are asked for the number of attempts to make. This is the number of time periods that you wish to have the radio powered up if no communication has occurred. Attempt count (1–10)<3> You are then asked to enter the wait time in minutes between attempts Wait between attempts(min) (1–60)<30> Finally you are asked to enter the time in minutes to leave the radio on after any communications. Wait after comm(min) (1–60)<1> As an example, if you select 10:30 for a start time, 10-minute wait for communication, 3 attempts, 30 minutes between attempts and wait for 1 minute after communication, the radio would be on for the following schedule if no communication is received: ON 10:30 11:10 11:50 OFF 10:40 11:20 12:00 If communication happens during one of the ON periods, the radio would remain on for 1 minute after the last communication and then turn off and remain off for the rest of the day. Versions 3:1.0 and later © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 75 In the Setup menu or the Edit Configuration/Edit Setup Data/Edit cycle Radio power? Menu selection the question to Daily cycle radio power allows you choose to cycle power. Daily cycle radio power?(Y/N)<N>y If you answer Y, you are asked to enter the start time for power cycling Start time<09:00> It may take your radio several seconds to power up after its power is turned on. To provide for this you are next asked to enter a stabilization time: Radio stabilization(seconds)(1-60)<50> You are now asked for the time to leave the radio ON while waiting for communication. The time can be a value between 1 and 1440 minutes (24 hours). On time(minutes)(1-1440)<10>120 Now you are asked for how long to leave the radio OFF. This may be set for a value between 1 and 1440 minus the On time. Off time(minutes)(1-1320)<1>60 You are now asked for how many On/Off cycles you wish. The number of cycles available is calculated by the length of your On and Off times. With a 2 hour ON time and a 1 hour Off time you could have 8 cycles in a day. Cycle count(1-8)<1>4 Next, you are asked if you want to continue the radio cycling after communication. If you answer N, the radio power will be turned OFF after the Time after comm time (see below) has expired and will not be turned ON until the next day. If you answer Y, the radio power will continue to be cycled ON and OFF as you select. Cycle after comm?(Y/N)<Y> You are now asked to enter the time in minutes to leave the radio ON after any communications. This leaves the radio ON even if the ON time period expires. Time after comm(minutes)(1-60)<5> Note: This extends the time period if a communication occurs close to the time to turn the radio OFF. If it is not close to the time to turn OFF, this has no effect. It does not turn the radio off in a cycle after the ON time period expires. Now you are asked to enter the time in minutes to leave the radio ON after a cryout. This will leave the radio ON even if the ON time period has expired. Time after cryout(minutes)(1-60)<3> Next, you are asked if you wish for the radio to be turned ON for cryout or for Cryout in cycle only (only when the radio is ON). Cryout in cycle only?(Y/N)<Y> Finally you are asked if you wish to cryout on no communications.. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 76 K500 Installation Manual Cryout on no comm?(Y/N)<N> As an example, if you select 10:30 for a start time, 10-minute ON time, 3 attempts, 30 minute OFF time and wait for 1 minute after communication, the radio would be on for the following schedule if no communication is received: ON 10:30 11:10 11:50 OFF 10:40 11:20 12:00 If communication happens during one of the ON periods and Cycle after comm. is answered N, the radio would remain on for 1 minute after the last communication and then turn off and remain off for the rest of the day. For another example, if you select 7:00 start time, 300-min. On time, 60 min. off time, 2 attempts, and continue cycle after comm. as Y, results in the following: ON 7:00AM 1:00PM OFF 12:00 6:00PM The cycle is the same even if communication occurs unless the communication is within 5 minutes of the off time. The setup is shown below: Edit RTU address?(Y/N)<N> Edit scrolling display delay? (Y/N)<N> Edit momentary relay duration? (Y/N)<N> Modify poll response?(Y/N)<N> Edit low power cutoff?(Y/N)<N> Edit cycle radio power?(Y/N)<Y> Daily cycle radio power(Y/N)<Y> Start time<09:00>07:00 Radio stabilization(seconds)(1-60)<50>10 On time(minutes)(1-1440)<60>300 Off time(minutes)(1-1140)<60> Cycle count(1-4)<2> Cycle after comm?(Y/N)<Y> Time after comm(minutes)(1-60)<5> Time after cryout(minutes)(1-60)<3> Cryout in cycle only?(Y/N)<Y> Cryout on no comm?(Y/N)<N> © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual 7.2.2 Page 77 Cycle radio power after inactivity Setup For versions prior to 3:1.0,the question to cycle the radio power after inactivity is in the setup menu. On later versions the question is also in the in the Edit Configuration/Edit Setup Data/Edit cycle Radio power? Menu and only appears if you have chosen not to cycle radio power. Daily cycle radio power?(Y/N)<Y>n The question to Cycle radio power allows you choose to cycle power to the radio after a period of inactivity. The power to the radio will be briefly turned off then back on. Cycle radio power after inactivity(Y/N)<Y> If you answer Y, you are asked to enter the time of inactivity before power cycling Time in hours(1-24)<1.5> 7.2.3 Cryout Versions prior to 3:1.0 In the setup menu you can enable cryout with the question to report on alarm. Report on alarm(Y/N)<Y> If you answer Y, you are asked to select the cryout conditions with the following questions: Report on alarm retry interval(secs) (1-3600)<30> Report on analog alarm(Y/N)<Y> Report on accumulator alarm(Y/N)<Y> Report on lift fail(Y/N)<Y> Report on fast lift(Y/N)<Y> Report on no comm(Y/N)<Y> The “Report on no comm” question allows you to select to cryout if you received no communication during the ON periods when using the daily power switching mode. When the K500 detects a cryout condition, it leaves the power down mode and cries out . It will stay in the power-on state for a selectable time waiting for an answering poll. You are next asked to enter this time. Wait for comm.(min)(1-60)<3> Note that it may take your radio several seconds to be able to transmit the cryout and this time is set with the “Radio turn on time” question in the power switch mode setup. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 78 K500 Installation Manual Versions 3:1.0 and later In the Setup Menu or the Edit Configuration/Edit Setup Data/Edit cryout? Menu you can enable cryout with the question to report on alarm. Report on alarm(Y/N)<N>y If you answer Y, you are asked to select the cryout conditions with the following questions: Report on alarm retry interval(secs) (1-3600)<30> Report on analog alarm(Y/N)<Y>y Report on accumulator alarm(Y/N)<Y> Report on status alarm(Y/N)<Y> Report on lift fail(Y/N)<N> The following two questions also appear on the Daily cycle radio power (refer to 7.2.1) Report on no comm(Y/N)<N> The “Report on no comm” question allows you to select to cryout if you received no communication during the ON periods when using the daily power switching mode. When the K500 detects a cryout condition, it leaves the power down mode and cries out (if the Cryout in cycle only? Question was answered N). It will stay in the power-on state for a selectable time waiting for an answering poll. You are next asked to enter this time. Wait for comm(min)(1-60)<3> Note that it may take your radio several seconds to be able to transmit the cryout and this time is set with the “Radio turn on time” question in the power switch mode setup. If you have selected conventional radio, you are asked to enter a delay time from when RTS is raised until the cryout is sent: Radio time out (secs)(0-1000)<0> If you have selected trunked radio you will be asked for Trunked radio time out and if you have selected modem you will be asked another set of questions. 7.2.4 Tank Stick Power Cycling Setup In the setup menu for versions prior to 3:1.0 or in the Edit Configuration/Edit Setup Data/Edit tank stick power? Menu in later versions, the question to switch tank stick power allows you choose to cycle power to the tank stick to conserve power. Tank Stick, switch power(Y/N)<Y> © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 79 If you answer Y, you are asked to select the period between power on periods with the following question: Tank stick, delay between attempts (sec)(5-3600)(60) If you select 60 seconds for example, the SAUX output of the K500 will be powered up every 60 seconds and will remain powered up only long enough to complete communicating with the tank stick. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 80 K500 Installation Manual © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 81 Appendix A - Specifications POWER Consumption Approximately 15mA at 13.5 V. (current will increase when LED's are lighted for Discrete (Digital) Inputs, Accumulator Input or Digital Outputs. Actuating a Discrete (Digital) Output Relay also increases current consumption. Battery: 12 Volt (11.5 to 18 V.), Charger K500 provides charging control for solar or AC charging sources with the optional charger card - Solar: 12 Volt, 100 Watt maximum - AC: 15 Volts, current limited to 5 A. MEMORY FLASH EPROM: 512K bytes RAM: 512K bytes ENVIRONMENT Temperature: -40 to +70C (-40 to +158F) Humidity: 0 to 95% relative humidity, non-condensing DISCRETE (DIGITAL) INPUT Channels: 4 with optional Digital I/O card Description: LED state indicator on each line. Compression type terminals. Dry contact sense current provided internally or externally. High = 8V minimum for a voltage input. DISCRETE (DIGITAL) OUTPUT Channels: 3 with optional Discrete (Digital) I/O card Description: Two Form C (SPDT) relays One Open Collector transistor output. LED state indicator on each line. Rating: Relays: 10A 125, 250 V ac 10A 30 V dc 1/3 HP 125, 250 V ac Open Collector Transistor: 0.75A 50 V dc © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 82 K500 Installation Manual ACCUMULATOR INPUT Channels: 1 with optional Discrete (Digital) I/O card Description: LED state indicator on input line. Compression type terminals. Jumper selectable filtering of none, 1000 Hz or 30 HZ. Dry contact sense or voltage input. High = 8V minimum for a voltage input ANALOG INPUT Channels: 3 with analog input card. One (battery voltage) without the card. Description: 2 high level inputs 1 to 5 V or 4 to 20 mA inputs Single pole 3 Hz hardware filter Protected multiplexing 1 dedicated input - Battery voltage Compression type terminals. 12 bit resolution A/D conversion COMMUNICATION Channels: 2 Rate: 150 to 9600 baud, software selectable Connector: RJ-45 on one port and DB9 on optional RS-232 Communication Card Interface Type: RS-232, DTE on two ports I/O RATINGS Auxiliary Output: 3 A, AGA3 Battery Input: 5 A, AGA5 Radio Power Switch: 3 A, AGA3 © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 83 Appendix B: Plunger Lift The K500 is ideally suited for plunger lift applications. The two analog inputs can be used for tubing and casing measurements, The Pulse input for the arrival sensor detection and the discrete (digital) outputs used for valve control. This can be either controlled flow using a Kimray EPC or EPVP or On/Off control with a solenoid valve. Figure B-1 Plunger Lift with EPC shows the wiring diagram for a typical plunger lift application using the Kimray EPC, Figure B-2 shows using a Kimray EPVP and Figure B-3 shows the wiring diagram using a solenoid valve. Note: A diode is required across the coil of the solenoid (refer to Appendix C). © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 84 K500 Installation Manual GND NOTE: TIE ALL SHIELDS TO THE GROUND LUG ON K500 BATT K500 MAIN ELECTRONICS CARD GND AUX 485485+ GND SAUX + TB1 V+ ARRIVAL SENSOR ACC+ OUT GND ACC- K500 DIGITAL IO CARD GND 0NC 0NO EPC OPEN CLOSE CLOSED SW OPEN SW 0COM 1COM 1NO 1NC 2COL VENT VALVE + - DI0 DI1 DI2 TUBING PRESSURE (1-5 V POWER Sensor) SIGNAL GND DI3 CASING PRESSURE (1-5 V POWER Sensor) SIGNAL GND GND TB2 TB1 0+ 0TB2 1+ K500 ANALOG INPUT CARD 1- Figure B-1 Plunger Lift with EPC © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual NOTE: TIE ALL SHIELDS TO THE GROUND LUG ON K500 Page 85 GND BATT K500 MAIN ELECTRONICS CARD GND AUX 485485+ GND SAUX + TB1 V+ ARRIVAL SENSOR ACC+ OUT GND ACC- K500 DIGITAL IO CARD GND 0NC 0NO EPVP OPEN CLOSE CLOSED SW SW COMMON OPEN SW 0COM 1COM 1NO 1NC 2COL VENT VALVE + TUBING PRESSURE (1-5 V POWER Sensor) SIGNAL GND CASING PRESSURE (1-5V POWER Sensor) SIGNAL GND DI0 DI1 DI2 DI3 GND TB2 TB1 0+ 0TB2 1+ K500 ANALOG INPUT CARD 1- Figure B-2 Plunger Lift with EPVP © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 86 K500 Installation Manual GND NOTE: TIE ALL SHIELDS TO THE GROUND LUG ON K500 BATT K500 MAIN ELECTRONICS CARD GND AUX 485485+ GND SAUX + TB1 V+ ARRIVAL SENSOR ACC+ ACC- OUT GND K500 DIGITAL IO CARD GND 0NC 0NO SOLENOID VALVE DIODE 0COM 1COM 1NO 1NC 2COL DI0 DI1 DI2 TUBING PRESSURE POWER SIGNAL GND CASING PRESSURE POWER SIGNAL GND DI3 GND TB2 TB1 0+ 0TB2 1+ K500 ANALOG INPUT CARD 1- Figure B-3 Plunger Lift with Solenoid Valve © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual Page 87 Appendix C: Switching current in a solenoid When a switch is closed to a solenoid, current flow is through the solenoid and switch as shown in Figure C-1. When the switch opens, the current flows through the diode and gradually goes to zero. If there is no diode, the current has no place to go and a very high voltage is generated on the solenoid wires. This can cause interference and damage and is the reason a diode is required across the coil of the solenoid. V V DIODE DIODE SOLENOID COIL SWITCH SOLENOID COIL SWITCH Figure C-1 Switching Current in a Solenoid If you are using a latching solenoid or motor winding where the polarity is reversed, a simple diode will not work. Figure C-2 is an example of this type of operation. One switch will ground one side of the coil while the other switch applies a voltage to the other side. This operation can put the voltage on either end of the solenoid so a bi-directional surge suppressor is recommended. One device that can be used is the P6KE18CA shown in the Figure. This provides back to back zener diodes which will prevent the voltage across the coil from being greater than 18 volts. © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 88 K500 Installation Manual V SOLENOID COIL P6KE18CA BI-DIRECTIONAL TRANSIENT VOLTAGE SUPPRESSOR V SOLENOID COIL P6KE18CA BI-DIRECTIONAL TRANSIENT VOLTAGE SUPPRESSOR Figure C-2 Switching Current in a Latching Solenoid © 2006 Kimray, Inc. (ENG-017 Rev. 1) K500 Installation Manual © 2006 Kimray, Inc. (ENG-017 Rev. 1) Page 89 October 18, 2006 © 2006 Kimray, Inc. (ENG-017 Rev. 1)