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)
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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)
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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)
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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)
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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)
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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)
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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)
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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)
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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)
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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)
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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)
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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.
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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
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K500 Installation Manual
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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
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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
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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
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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
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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
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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>
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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.
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K500 Installation Manual
© 2006 Kimray, Inc. (ENG-017 Rev. 1)
K500 Installation Manual
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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)
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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..
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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
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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)
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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
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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.
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© 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 +70C (-40 to +158F)
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)