user instructions · ips smart rtu english 701-4101-01^ 6-14 page 3 of 24 flowserve.com 1...

USER INSTRUCTIONS

IPS Smart RTU Installation

Operation

Maintenance Multiple Sensor Input and Wireless Transmitting Unit

PCN = 26999987 6-14 (E). Original Instructions

These instructions must be read prior to installing, operating, using and maintaining this equipment.

701-4101-01^

IPS SMART RTU ENGLISH 701-4101-01^ 6-14

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CONTENTS

1 INTRODUCTION AND SAFETY .......................... 3

1.1 GENERAL ......................................................... 3 1.2 CE MARKING AND APPROVALS .......................... 3 1.3 DISCLAIMER ..................................................... 3 1.4 COPYRIGHT ...................................................... 3 1.5 DUTY CONDITIONS ............................................ 3 1.6 SAFETY ............................................................ 4 1.7 SPECIFIC MACHINE PERFORMANCE .................... 4 1.8 SPECIFICATIONS ............................................... 4

2 TRANSPORT AND STORAGE ............................ 5

2.1 CONSIGNMENT RECEIPT AND UNPACKING ............ 5 2.2 HANDLING ......................................................... 6 2.3 STORAGE .......................................................... 6 2.4 RECYCLING AND END OF PRODUCT LIFE .............. 6 2.5 DISPOSAL INSTRUCTIONS ................................... 6

3 DESCRIPTION ..................................................... 6

3.1 OPTIONS AND MODEL NUMBERS ......................... 7 3.2 DEFAULT CONFIGURATION ................................ 8 3.3 PERFORMANCE AND OPERATION LIMITS .............. 8 3.4 VB-103-TAM OPTIONAL ACCESSORY ............... 8 3.5 OVERALL VISUAL ALERT LIGHT (RTU-OVAL)

OPTIONAL ACCESSORY ..................................... 8 3.6 INDIVIDUAL SENSOR ALERT LIGHT (RTU-SAL-

X) OPTIONAL ACCESSORY ................................. 9 3.7 INDIVIDUAL BACKLIT SENSOR INFORMATION

DISPLAY (RTU-SID-X) OPTIONAL ACCESSORY .. 9

4 MAINTENANCE ................................................... 9

4.1 TOOLS REQUIRED ............................................. 9 4.2 TURNING UNIT ON/OFF ...................................... 9 4.3 BATTERY REPLACEMENT ................................... 9

5 CUSTOM CONFIGURATION PROGRAMMING 10

6 INSTALLATION .................................................. 10

6.1 TOOLS REQUIRED ........................................... 11 6.2 UNPACKING .................................................... 11 6.3 PRELIMINARY OPERATIONAL CHECK ................. 11 6.4 INSTALLATION PREPARATION ........................... 11 6.5 MOUNTING ..................................................... 12 6.6 CONNECTING SENSORS AND POWER-UP ......... 12 6.7 CONNECTING TAKE AWAY MEMORY ................. 13 6.8 VISUAL ALERT ACCESSORIES .......................... 13

7 PARTS LIST AND DRAWINGS ......................... 13

7.1 SPARE PARTS ................................................ 13 7.2 DRAWINGS ..................................................... 14

8 CERTIFICATIONS ............................................. 18

9 TROUBLE-SHOOTING GUIDE ......................... 18

9.1 LOSS OF COMMUNICATIONS ............................ 18

9.2 INACCURATE OR MISSING DATA ....................... 19 9.3 NO DATA RECORDED ON VB-103-TAM ........... 19 9.4 NO LIGHTS ON LIGHTS OR DISPLAY

ACCESSORIES ................................................ 19

10 DECLARATION OF CONFORMITY (TYPICAL)21


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1 INTRODUCTION AND SAFETY

1.1 General

These instructions must always be kept close to the product's operating location or directly with the product. Flowserve products are designed, developed and manufactured with state-of-the-art technologies in modern facilities. The unit is produced with great care and commitment to continuous quality control, utilizing sophisticated quality techniques, and safety requirements. Flowserve is committed to continuous quality improvement and being at your service for any further information about the product in its installation and operation or about its support products, repair and diagnostic services. These instructions are intended to facilitate familiarization with the product and its permitted use. Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks. The instructions may not take into account local regulations; ensure such regulations are observed by all, including those installing the product. Always coordinate repair activity with operations personnel, and follow all plant safety requirements and applicable safety and health laws/regulations.

These instructions must be read prior to installing, operating, using and maintaining the equipment in any region worldwide. The equipment must not be put into service until all the conditions relating to safety, noted in the instructions, have been met. Failure to follow and apply the present user instructions is considered to be misuse. Personal injury, product damage, delay or failure caused by misuse are not covered by the Flowserve warranty.

1.2 CE Marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and Equipment for Potentially Explosive Atmospheres (ATEX).

Where applicable, the Directives and any additional Approvals, cover important safety aspects relating to machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable this document incorporates information relevant to these Directives and Approvals. To confirm the Approvals applying and if the product is CE marked, check the serial number plate markings and the Certification. (See section 8 CERTIFICATIONS.)

1.3 Disclaimer Information in these User Instructions is believed to be complete and reliable. However, in spite of all of the efforts of Flowserve Corporation to provide comprehensive instructions, good engineering and safety practice should always be used. Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assurance organizations. Genuine parts and accessories have been designed, tested and incorporated into the products to help ensure their continued product quality and performance in use. As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products. The failure to properly select, install or use authorized Flowserve parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by the Flowserve warranty. In addition, any modification of Flowserve products or removal of original components may impair the safety of these products in their use.

1.4 Copyright All rights reserved. No part of these instructions may be reproduced, stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve.

1.5 Duty conditions This product has been selected to meet the specifications of your purchase order. The acknowledgement of these conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.


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The product must not be operated beyond the parameters specified for the application. If there is any doubt as to the suitability of the product for the application intended, contact Flowserve for advice. If the conditions of service on your purchase order are going to be changed (for example: liquid pumped, temperature or duty) it is requested that the user seeks the written agreement of Flowserve before start up.

1.6 Safety 1.6.1 Summary of safety markings These User Instructions contain specific safety markings where non-observance of an instruction would cause hazards. The specific safety markings are:

This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life.

This symbol indicates safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates “hazardous and toxic fluid” safety instructions where non-compliance would affect personal safety and could result in loss of life.

This symbol indicates safety instructions where non-compliance will involve some risk to safe operation and personal safety and would damage the equipment or property.

This symbol indicates explosive atmosphere zone marking according to ATEX. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

This symbol is used in safety instructions to remind not to rub non-metallic surfaces with a dry cloth; ensure the cloth is damp. It is used in safety instructions where non-compliance in the hazardous area would cause the risk of an explosion.

This sign is not a safety symbol but indicates an important instruction in the assembly process.

1.6.2 Personnel qualification and training All personnel involved in the operation, installation, inspection and maintenance of the unit must be qualified to carry out the work involved. If the personnel in question do not already possess the necessary knowledge and skill, appropriate training and instruction must be provided. If required the operator may commission the manufacturer/supplier to provide applicable training. Always coordinate repair activity with operations and health and safety personnel, and follow all plant safety requirements and applicable safety and health laws and regulations. 1.6.3 Safety action This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment. For products used in potentially explosive atmospheres section 1.6.4 also applies.

NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER (Lock out.)

HANDLING COMPONENTS Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components. To lift heavy pieces above 25 kg (55 lb.) use a crane appropriate for the mass and in accordance with current local regulations. 1.6.4 Products used in potentially explosive atmospheres

Measures are required to:

Avoid excess temperature

Prevent buildup of explosive mixtures

Prevent the generation of sparks

1.7 Specific machine performance For performance parameters see section 1.5 Duty conditions. Where performance data has been supplied separately to the purchaser these should be obtained and retained with these User Instructions if required.

1.8 Specifications 1.8.1 Smart RTU Unit Specifications Operating frequency: 900 MHz or 868MHz Channels: 2, 4, 6 or 8 Transmission rates: 5 seconds or higher Operating range: 0.75 mile (1.21km)


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Operating temperature:

-4°F to +104°F (-20°C to +40°C)

Channel output power:

16 to 24VDC

Channel output time: Programmable Humidity: 0-95% noncondensing Inputs: 4-20mA, discrete, 0-

1VDC by channel Power requirement: 12 or 24VDC, 110VAC

or 220VAC Enclosure: Fiberglass NEMA 4X

(size dependent on accessories ordered)

Weight: (Solar Power) 15.50 lb (7.06kg) (Battery or accessories not included)

Weight: (AC Power) 15.00 lb (6.80kg) (Battery or accessories not included)

1.8.2 Optional add-on sensor specifications RTD: 1000 or 100 Ohm

(Platinum, 2 wire) Thermocouple: Type: J, K, N, T, etc. (+

Cold Reference & Polynomial)

Pressure: Vacuum to 10Kpsi (Specific sensor for each range)

Vibration (Velocity): Single Axis, Tri Axis (0-1 ips) (0-25 mm/sec)

Vibration: (Acceleration):

0 - 10G Peak

Discrete: Dry Contact Only 1.8.3 Optional RTU-OVAL specifications Channels: 1 to 6 1.8.4 Optional RTU-SAL-X specifications Channels: 1 to 6 Humidity: 50% at 104°F (40°C) Power requirement: 24VDC, 110VAC or

220VAC Channel output power:

24VDC

Expected Lamp Life: 100,000 Hours Sensor Input Types: Vibration (overall 4-

20mA signal), Thermocouples, RTD (PT100, PT1000), Pressure, 4-20mA, Discrete, Oil/Water, Proximity Probes

1.8.5 Optional RTU-SID-X specifications Channels: 1 to 6 Operating Humidity: 0-90% noncondensing Power requirement: 24VDC, 110VAC or

220VAC Channel output power:

24VDC

Sensor Input Types: Vibration (overall 4-20mA signal), Thermocouples, RTD (PT100, PT1000), Pressure, 4-20mA, Discrete, Oil/Water, Proximity Probes

Display Digits: Four digits, 0.25” (6.4mm) high in pre-specified engineering units

Display Accuracy: ± 0.03% of span ± 1 count

Backlight: Orange (intensity varies with signal)

Error Display: Display flashes “99999” for over-range and “-99999” for under-range inputs

2 TRANSPORT AND STORAGE

Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used. The safety specifications must be in accordance with the current local regulations at all times.

2.1 Consignment receipt and unpacking Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its completeness and that there has been no damage in transportation. Any shortage and/or damage must be reported immediately to Flowserve and must be received in writing within ten days of receipt of the equipment. Later claims cannot be accepted. Check any crate, boxes or wrappings for any accessories or spare parts that may be packed separately with the equipment or attached to side walls of the box or equipment.

Each product has a unique serial number. Check that this number corresponds with that advised and always quote this number in correspondence as well as when ordering spare parts or further accessories.


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2.2 Handling Boxes, crates, pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction.

2.3 Storage

Store the equipment in a clean, dry location. The Smart RTU should be powered-down prior to storage (see section 4 MAINTENANCE for how to power down unit) to preserve battery life.

2.3.1 Storage and packaging All Smart RTU units must be carefully packaged for transport. Each unit should be boxed individually with protective packaging (foam, bubble wrap, etc.) in the box surrounding the unit. After unpacking, protection will be the responsibility of the user.

2.4 Recycling and end of product life At the end of the service life of the product or its parts, the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and in accordance with local regulations. If the product contains substances that are harmful to the environment, these should be removed and disposed of in accordance with current local regulations.

2.5 Disposal Instructions

At the end of the product’s life, do not dispose of any electronic component or instrument in the domestic waste. Disposal should be done in accordance with applicable regulations, which vary from state to state and country to country. Battery Disposal Instructions: Disposal should be done in accordance with applicable regulations, which vary from country to country. Batteries should not be incinerated, unless suitable procedures are followed and qualified handlers have taken appropriate precautions. Exposure of these cells to high temperatures or fire can cause the cells to vent and/or rupture. These cells do not contain dangerous substances. The reaction products are inorganic and do not represent environmental hazards, once the decomposition or neutralization process has terminated.

Disposal in Europe Batteries for disposal should not be transported by air. For road transport of dangerous goods ADR special provision 636 and packing instruction 903a apply. Disposal in US Hazardous waste of spent batteries can be disposed after they are first neutralized through an approved secondary treatment prior to disposal. Disposal of spent batteries should be performed by authorized, professional disposal company, which has the knowledge in the requirements of the Federal, the State and the Local authorities regarding hazardous materials, transportation and waste disposal. In any case it is recommended to contact the local EPA office.

3 DESCRIPTION The IPS Smart RTU model is a wireless transmitting unit designed to monitor multiple analog, discrete or IPS Wireless sensor inputs and wirelessly transmit the data to a receiver. It has the option of enabling wireless transmission (to become part of an IPS Wireless system) or disabling wireless functionality (to perform as a local alert or data-logging unit).

Figure 1: Sample Smart RTU unit The Smart RTU is either powered by a solar panel or AC power and includes a built-in automatic battery back-up system. It can monitor up to 8 different channels (dependent on accessories ordered) of analog, digital or IPS Wireless sensor inputs. The exact type of sensors monitored on each channel is dependent on the individual unit configuration. Consult factory for any applications that require more than 8 channels per Smart RTU.

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At the pre-configured transmission time, the Smart RTU reads the sensor data on a single channel, transmits it and the moves on to the next channel until all the channels have been read and data transmitted. Each unit also has a single diagnostics port (inside the enclosure) for programming and troubleshooting the unit as well as logging data with the VB-103-TAM accessory (where collected data is stored). Programming the unit requires a programming cable and special software utility (PSP).

The Smart RTU has a built-in omni-directional wireless antenna, allowing for reliable signal transmission. Data transmittal can occur at a customizable time interval, ranging from every 5 seconds to once a day (this time interval is usually pre-configured at the factory). Transmission rates can also be varied according to sensor signal values (see section 5 CUSTOM CONFIGURATION PROGRAMMING), thereby prolonging battery life. The Smart RTU has a maximum data transmittal range of ¾ mile (1.2km) under ideal conditions, but its effective transmission range can be extended using a network of repeaters. Each Smart RTU can be part of a larger wireless monitoring network. As such, each unit comes with a calibration sheet from the factory which contains unit-specific configuration information describing the sensors and wireless network the unit is configured for (parameters such as the wireless system number, unit transmitter number, data transmittal/check-in interval, scale factor and offset to use with specific sensors). As long as your specific application has been communicated to the factory, the Smart RTU unit should come pre-configured for your specific use.

3.1 Options and model numbers The Smart RTU can either have wireless data transmission enabled or disabled. In both settings, certain accessories are only compatible with AC powered Smart RTUs (see Table 1: Optional parts for Smart RTU). Smart RTU units with wireless transmission disabled are intended for use as local data collectors with either the take away memory (VB-103-TAM) or visual light alert modules. The Smart RTU is available with the following sensors as options to connect to inputs on the unit:

1. Vibration & Temperature (RTD) Combination

Sensor

2. Vibration Sensor

3. Temperature Sensor (RTD)

4. Temperature Sensor (Thermocouple)

5. Pressure Sensor

6. 4-20mA Analog Input Sensor

7. General Pulse Input Sensor

8. Tachometer (TTL)

9. Discrete Sensor

10. Vibration Sensor with FFT analysis output

11. Oil/Water Sensor

12. Proximity Probes

13. Serial Port RS-485 Interface

Additionally the Smart RTU has the following options available: Table 1: Optional parts for Smart RTU

Part Number Description

301-4024 Programming cable: 5’ length, Serial Port- RS-485 connection

PSP Unit Configuration Software Utility

VB-103-TAM Take-Away Memory Module

VB-101-DOCK IPS Dock for communication with VB-103-TAM Take-Away Memory Module

TAM103 Utility VB-103-TAM data download and configuration software

RTU-OVAL (only available on AC powered Smart RTU)

Overall Visual Alert Light

RTU-SAL-X (only available on AC powered Smart RTU, X designates the number of sensors to have alert lights)

Sensor Alert Light (per input)

RTU-SID-X (only available on AC powered Smart RTU, X designates the number of sensors to have alert lights)

Backlit Sensor Information Display (per input)

The exact configuration of different sensors attached to each Smart RTU unit is limited to certain combinations. Contact the factory for a


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complete list of the different configurations available for the Smart RTU.

3.2 Default Configuration The Smart RTU is configured to the following parameters by default, unless otherwise specified. Table 2: Parameter default configuration values for Smart RTU

Parameter Name

Parameter Description

Default Value

Normal Measurement Interval

How often data is read from each of the sensors by the Smart RTU

5 minutes

3.3 Performance and operation limits This product has been selected to meet the specification of your purchase order. The following data is included as additional information to help with your installation. This is typical information and if required, a definitive statement for your application can be obtained from Flowserve.

Smart RTU material compatibility is the responsibility of the end user. 3.3.1 Sensor specifications Refer to section 1.8 Specifications for available sensor specifications. 3.3.2 Battery

Power is provided by a user-replaceable sealed lead acid 12V battery, located inside the Smart RTU enclosure. Battery life is dependent upon data transmittal intervals and charging system operation. Battery voltage should normally be between 12.0 and 12.8VDC. If it is lower than 11V, the battery will need to be replaced with the one specified on the wiring diagram. The battery voltage can be read using a voltmeter (with the charging system fuse opened). The battery is then charged by either a solar panel or an AC power supply (dependent on specific unit). Typically the battery is expected to last 5 years, if the charging system is properly functional.

3.4 VB-103-TAM Optional Accessory The VB-103-TAM is an optional Take Away Memory module for the Smart RTU. When connected to a Smart RTU, it automatically logs

data from all sensors at the preconfigured log interval. Data from the VB-103-TAM and the log interval can be reviewed utilizing an IPS Dock connected to a PC. The VB-103-TAM is set to a default log interval (how often current data from the Smart RTU is logged to the VB-103-TAM device) of 5 minutes (300 seconds), unless otherwise specified. This is independent of the normal measurement interval of the Smart RTU which governs how often sensors are read.

The battery logged on the VB-103-TAM unit represents an internal voltage being supplied to the RTU board. This battery voltage reading should normally be around 3.3V and is not directly representative of the RTU battery-backup voltage or AC/solar power supply voltage.

The VB-103-TAM has a separate battery that governs the lifetime of this unit. The expected life of this battery is 6 years at the default 5 minute log interval. The battery in the VB-103-TAM is not replaceable and requires replacing the VB-103-TAM unit when it is depleted. The VB-103-TAM also has a finite amount of data storage available. Dependent on the amount of data points being measured and the measurement interval, this storage capacity is defined as listed in the table below. Table 3: VB-103-TAM data storage capacity at various measurement intervals and numbers of data parameters

Measurement Interval

Data Points

5 s 10 s 30 s 1 min

2 min

5 min

10 min

1 50 day

100 day

10 mo

1.6 yrs

3.3 yrs

4 yrs 4 yrs

2 25 day

50 day

5 mo

10 mo

1.6 yrs

4 yrs 4 yrs

3 16 day

33 day

3.3 mo

6.6 mo

1.1 yrs

2.7 yrs

4 yrs

4 12 day

25 day

2.5 mo

5 mo

10 mo

2 yrs 4 yrs

5 10 day

20 day

2 mo

4 mo

8 mo

1.6 yrs

3.3 yrs

6 8 day

16 day

50 day

100 day

6.6 mo

16.6 mo

2.7 yrs

7 7 day

14 day

42 day

2.8 mo

5.7 mo

14.2 mo

28.5 mo

3.5 Overall Visual Alert Light (RTU-OVAL) Optional Accessory The Overall Visual Alert Light (RTU-OVAL) is an optional accessory for the Smart RTU. When connected to a Smart RTU, it automatically


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provides a visual light indication if any sensors on the Smart RTU unit are or have been in alarm status. To define the alarm limits for each sensor, refer to Section 5 CUSTOM CONFIGURATION PROGRAMMING. The table below describes each of the different types of indications offered by the RTU-OVAL accessory. Table 4: RTU-OVAL visual alert description

LED State Description

GREEN

Light flashes on for 400 milliseconds

Normal operation – all sensors are within acceptable limits

RED

Light flashes on for 400 milliseconds

Current alarm – one of the sensor measurements has exceeded its alarm limit and has not returned within the acceptable range

RED & GREEN

Each color light flashes on for 400 milliseconds

Alarm – one of the sensor measurements previously exceeded its alarm limit, but has now returned within the acceptable range

The time period for which the RTU-OVAL lights will flash to indicate a past alarm event is set to 14 days by default.

3.6 Individual Sensor Alert Light (RTU-SAL-X) Optional Accessory The Individual Sensor Alert Lights (RTU-SAL-X) are an optional accessory for the Smart RTU. When installed in a Smart RTU, each light automatically provides a visual light indication if its particular sensor is in alarm status. Each sensor on the Smart RTU requires its own Sensor Alert Light. To define the alarm limits for each sensor, refer to Section 5 CUSTOM CONFIGURATION PROGRAMMING.

3.7 Individual Backlit Sensor Information Display (RTU-SID-X) Optional Accessory The Individual Backlist Sensor Information Displays (RTU-SID-X) are an optional accessory for the Smart RTU. When installed in a Smart RTU, each display shows the actual current applicable sensor reading in the predefined engineering units. Each sensor on the Smart RTU requires its own Sensor Information Display. Refer to the Smart RTU test sheet to determine the engineering units configured for each sensor.

4 MAINTENANCE The only field maintenance required on the Smart RTU is checking the battery and charging system.

The Smart RTU can also be turned off when not in use for extended periods of time to conserve battery life.

4.1 Tools required Set of SAE wrenches

Phillips head screwdriver

Small flat-head screwdriver

Voltmeter

4.2 Turning unit on/off To power off Smart RTU disconnect the fuse for the battery cables and the wires coming from the power supply or solar panel (refer to included wiring diagram to identify the correct fuse blocks). This will stop sensor readings and data transmission. To power up the Smart RTU again, simply reconnect the battery and power supply or solar panel fuses inside the enclosure (refer to included wiring diagram to identify the correct fuse blocks). This will activate sensor readings and data transmission at the pre-configured intervals.

Figure 2: Fuses on inside of Smart RTU enclosure

4.3 Battery Replacement

EXPLOSION HAZARD: Do not open enclosure when an explosive atmosphere may be present. The unit must be powered OFF during the battery installation.

WARNING STATIC HAZARD: Wipe only with a damp cloth due to electrostatic discharge hazard.

The substitution of components may impair intrinsic safety.


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Power is provided by a sealed lead acid 12V battery located inside the Smart RTU enclosure. The battery is then charged by either a solar panel or an AC power supply (dependent on specific unit). Battery voltage should normally be between 12.0 and 12.8 VDC. If the battery level is lower than 11V, the battery will need to be replaced. The battery voltage can be read by using a voltmeter (with the charging system fuse opened).

The battery pack shall only be replaced with PowerSonic model numbers PS-12180 (for a solar powered Smart RTU) or PS-1270 (for AC powered Smart RTU). Replacement batteries can also be obtained by contacting your local Flowserve representative (battery pack part numbers G1-0005 & G1-0004). Perform the following steps to replace the battery: 1. Ensure an explosive atmosphere is not

present, and then open the cover of the Smart RTU enclosure.

2. Power down unit by removing the battery and power supply/solar panel fuses inside the enclosure.

3. Disconnect the wires connecting to the battery terminals.

Figure 3: Wires going to battery terminals inside Smart RTU enclosure 4. Remove old battery and place new battery

inside enclosure. 5. Connect battery cables to terminals of new

battery. 6. Reconnect battery and power supply/solar

panel fuses. 7. Ensure Smart RTU powers up, then close

enclosure cover. 8. Dispose of old battery in accordance with local

laws and regulations.

5 CUSTOM CONFIGURATION PROGRAMMING

This section is optional. As long as your specific application was communicated to the factory prior to shipment, the Smart RTU unit is pre-configured for your specific use.

Errors in programming configuration can render the Smart RTU inoperable, proceed with caution. Flowserve is not liable for any damage caused by user configuration errors. For instructions on how to change software configuration options on the Smart RTU, refer to the PSP software user instructions. The list below provides an overview of the functions that can be performed using this software utility:

- Reading & saving Smart RTU configuration - View & modify Smart RTU transmission

intervals - Setting the time on the Smart RTU - Calibration of individual sensors on Smart

RTU - Read live data from sensors on the Smart

RTU - Change alarm levels on the Smart RTU

(also affecting the RTU-OVAL accessory)

- Turn specific Smart RTU sensor channels on or off

For instructions on how to perform software options on the VB-103-TAM unit, refer to the IPS Dock user instructions. The list below provides an overview of the functions that can be performed using the IPS Dock and appropriate software utility:

- Reading & saving VB-103-TAM log data - Clearing the log from the VB-103-TAM - Setting the time on the VB-103-TAM - Changing the data logging interval on the

VB-103-TAM

For instructions on how to change the alarm levels for the RTU-SAL-X optional accessory, refer to the signal conditioning module user instructions. Note: this will require a special programming cable and software utility.

6 INSTALLATION

Always wear appropriate personal protective equipment during the installation of Smart RTU units.


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6.1 Tools required Tools required to install the various

mounting configurations are conditional based on the type of mounting and location

Set of SAE wrenches

Phillips head screwdriver

Small flat-head screwdriver

Voltmeter

6.2 Unpacking

Carefully open package received from factory and remove protective wrapping from Smart RTU units and accessories. Inspect all hardware for damage. Report any damage to shipping carrier immediately. Ensure you have received the correct sensors and mounting accessories for your application. Cross-check hardware received versus packing slip and purchase order. Record unit serial numbers for future reference. 6.2.1 Electrostatic Discharge (ESD) Handling Procedure

The Smart RTU contains sensitive electronic components that may be damaged by static electricity present in work environments. The following precautions are recommended to reduce the risk of damage due to electrostatic discharge:

Only wipe exterior of unit with a damp cloth

Use of a grounding wrist strap when removing inner enclosure cover is recommended

6.3 Preliminary operational check After unpacking and before field installation, perform the following operational check on the unit: 1. Ensure the fuse for the battery is disconnected.

This keeps the unit powered down during the installation process.

2. Place Smart RTU in vertical position with a clear line of sight to and close to (< 3.048 m (<10 ft.)) the receiver. If only using the VB-103-TAM or local display accessories, simply place Smart RTU in a vertical position.

3. Insert sensor wire(s) into the proper terminals. 4. Ensure battery is connected to battery terminal

wires, and then connect the battery fuse to power up the unit. Install the VB-103-TAM to the Smart RTU (if applicable).

5. Ensure the receiver is receiving data from the unit. If applicable, let the VB-103-TAM log data for a few minutes and confirm appropriate light operation of the light and data display units as applicable.

6. If applicable, disconnect VB-103-TAM and use IPS Dock to confirm accurate data has been logged (refer to IPS Dock user instructions for how to do this).

7. Disconnect fuse for the battery to power down the unit. Disconnect and remove battery.

8. Disconnect sensor wire(s) from terminals.

In case of issues with powering up the unit, refer to section 9 Trouble-Shooting Guide.

6.4 Installation Preparation Prior to mounting the Smart RTU in the field, two penetrations will need to be drilled in the enclosure to accommodate connections for power and sensor wiring. It is recommended that the penetrations be drilled in the bottom of the enclosure to minimize moisture and/or dust entry to the enclosure. Two penetrations are needed to be able to route the power and sensor wiring through separate conduits. The size of each penetration is user-dependent, they should be large enough to accommodate all the cables to be run through each penetration. Penetrations should be made in accordance with the local electrical wiring code (such as NEC/CEC). While penetrating the enclosure and installing the fittings, take care not to damage the internal wiring and boards of the Smart RTU.

Figure 4: Inside of Smart RTU enclosure with penetrations made


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Figure 5: Outside of bottom portion of Smart RTU enclosure with conduit going into penetrations in enclosure

6.5 Mounting Each unit should be clear of physical obstructions to the receiver and/or repeater(s) in order to maintain consistent communications (if applicable). If the Smart RTU is solar powered, a location with at least 6 hours of unobstructed daily sunlight and an equatorial exposure should be considered. The Smart RTU is designed to be mounted in a vertical position and should only be mounted in a horizontal position with approval from the factory. Ensure the Smart RTU is not subjected to excessive vibration unless a routine maintenance program includes verification of associated connections. The Smart RTU unit should be installed near but not on process equipment being monitored. Mount the Smart RTU unit before connecting any of the sensor cables. The Smart RTU is designed to be bolted to 2 pieces of horizontal unistrut. First, both these pieces of unistrut should be mounted horizontally to a support structure (poles, pipe, hand-rail, wall, etc) using the necessary hardware (U-bolts, studs, bolts, etc). Then, use the mounting holes on the back of the Smart RTU enclosure to bolt the unit to the pieces of unistrut. Next, if applicable, install the solar panel facing the equator with a tilt (from horizontal) of about 15 degrees plus your location’s latitude.

Figure 6: Sample installed solar powered Smart RTU

6.6 Connecting Sensors and Power-Up Install all sensors on equipment to be monitored. Wiring for the solar panel or AC power should be run into the Smart RTU through an enclosure penetration. Terminate these wires according to the local electrical wiring code (such as NEC/CEC), but do not connect them to the terminal blocks yet. Run sensor wiring through a separate conduit into a separate penetration into the Smart RTU. Terminate these wires and connect them to the appropriate terminal blocks according to the wiring diagram supplied with your particular Smart RTU unit. 4-20mA current signals can be wired 3 different ways depending on the type of sensor. For a loop powered 4-20mA device, connect wires as follows:

- Connect the positive (power supply) of sensor wire to the 24VDC+ terminal block

- Connect negative (signal) of sensor wire to channel Signal+ terminal block

For a 3-wire 4-20mA device, connect wires as follows:

- Connect positive signal wire to channel Signal+ terminal block

- Connect negative wire to channel COM (or Signal-) terminal block

- Connect power wire to 24VDC+ terminal block


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For a 4-wire 4-20mA device, connect wires as follows:

- Connect positive of sensor wire to channel Signal+ terminal block

- Connect negative of sensor wire to channel COM (or Signal-) terminal block

- Connect sensor external power positive wire to the 24VDC+ terminal block

- Connect sensor external power negative wire to COM terminal block

Ensure all sensor wires are connected to the terminal blocks first. Then, connect the AC or solar panel wires to the appropriate terminal blocks. Next, install the battery inside the enclosure and connect the Battery+ and Battery- wires to the terminals. Close all fuses to power up the unit.

Figure 7: Sample Smart RTU unit with sensor wires connected to terminal blocks

6.7 Connecting Take Away Memory Open the Smart RTU enclosure and install the VB-103-TAM into the amphenol-style connection on the backpanel. The VB-103-TAM will automatically start logging data from the Smart RTU unit at its preconfigured log interval. Close the Smart RTU enclosure. To change the logging interval or download data from the VB-103-TAM, refer to the IPS Dock User Instructions.

6.8 Visual Alert Accessories The Overall Visual Alert Light (RTU-OVAL), Individual Sensor Alert Light(s) (RTU-SAL-X) and

Individual Sensor Information Display(s) (RTU-SID-X) are already installed on the Smart RTU unit if ordered. They do not require any further installation or configuration. These accessories should only be installed or uninstalled by the factory. The RTU-OVAL Module will automatically reflect the alarm status of all sensors on the Smart RTU. The RTU-SAL-X light(s) will turn on to provide a visual light indication if the applicable sensor is in alarm status. To define the alarm limits for each sensor, refer to Section 5 CUSTOM CONFIGURATION PROGRAMMING. The RTU-SID-X display(s) will show the actual current applicable sensor reading in the predefined engineering units.

7 PARTS LIST AND DRAWINGS

7.1 Spare Parts Available spare parts for the Smart RTU unit are shown below. No spare parts are needed during start-up. Recommended quantities of 2-year operational spares are listed below. Table 5: Smart RTU Spare Parts

Part Number

Description Recommend Quantity for

2-Year Operational Spares

G1-0005 (for solar powered RTU)

Replacement Battery, 12V, 18Ah

1

G1-0004 (for AC powered RTU)

Replacement Battery, 12V, 7Ah

1

G2-0003 (for solar powered RTU)

Replacement Solar Panel, 12V, 20W

1

H0-0122 Replacement fuse, 0.5A 2

H0-0129 Replacement fuse, 2.5A 2

H0-0131 Replacement fuse, 0.0 32A

6

M1-0085 SS cap for VB-103-TAM connection ports (single)

1


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7.2 Drawings

Figure 8: AC Powered Smart RTU drawing


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Figure 9: Solar Powered Smart RTU


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Figure 10: Smart RTU with RTU-OVAL, RTU-SAL and RTU-SID accessories


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Figure 11: Inside of Smart RTU with RTU-OVAL, RTU-SAL and RTU-SID accessories


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8 CERTIFICATIONS The following certifications are applicable to the Smart RTU: Table 6: Smart RTU (Model S-EGI-NB-4/20RTU) certifications

0518 II 3 GD

Ex nA IIC T6 Cl I, Div 2, Grp A,B,C,D; Cl II, Div2, Grp E,F,G, T6 Cl I, Zone 2, A/Ex nA IIC T6 Type 4X -20°C ≤ Ta ≤ +40°C

Electrical Ratings: 115/230 Vac, 1.3/0.7A, 50-60 Hz CAUTIONS: OPEN CIRCUIT BEFORE REMOVING COVER. KEEP COVER TIGHT WHILE CIRCUITS ARE LIVE. WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2. DO NOT DISCONNECT BATTERY OR EQUIPMENT UNLESS THE AREA IS KNOWN TO BE NON-HAZARDOUS. USE ONLY POWER SONIC BATTERY PART NUMBER PS-1270 OR PS-12180.

9 TROUBLE-SHOOTING GUIDE

EXPLOSION HAZARD: The unit must be powered OFF during the battery installation & must be in a General Purpose Classified Area before opening outside enclosure to prevent the possible ignition of a hazardous atmosphere.

9.1 Loss of Communications Loss of communications with Smart RTU unit may occur for several reasons:

Unit not powered up

Unit not configured correctly

Unit out of range of receiver

Receiver not configured correctly

See solutions below to each of the possible causes: 9.1.1 Unit Not Powered Up Verify battery and power supply/solar panel fuses are connected and not blown (refer to included wiring diagram for where these fuses are located). 1. Open the power supply/solar panel fuse. 2. Read battery level using voltmeter connected

to battery terminals. If the battery level is below 11V, replace the battery according to instructions in section 4 MAINTENANCE.

3. If communications are still not successful, confirm the power source being used to charge the battery. This procedure will vary depending

on if your unit has a solar panel or AC power input.

a. AC Power: confirm the voltage coming out of the 24V power supply is close to 24VDC. If there is no output from the power supply, confirm that AC power is connected to the power supply. If the AC power connection is working, the power supply will need to be replaced. Contact the

Flowserve factory for assistance. b. Solar Panel: confirm the power

coming out of the power regulator is 12VDC or higher. If there is no output from the regulator, confirm that the solar panel is connected to the input and functional. If the solar panel supply is working, the voltage regulator will need to be replaced. Contact the Flowserve factory for assistance.

Figure 12: Measuring AC power supply output on Smart RTU using a voltmeter 9.1.2 Unit Not configured Correctly To perform the diagnostic steps for this issue, the Smart RTU unit will need all sensors connected to it.

Refer to PSP software instructions to reload the original configuration into the Smart RTU unit. 9.1.3 Unit Out of Range of Receiver

If communications from the Smart RTU unit to the

receiver are still not successful, physically move the Smart RTU unit next to and with a clear line of sight to the receiver.


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If data is being read from this location, then ensure that the repeater network is appropriately located and functional.

9.1.4 Receiver Not Configured Correctly Check receiver configuration to ensure it is set up to receive data from this particular Smart RTU unit (refer to receiver user instructions).

If none of the above solutions are successful in getting data reception at the receiver, contact the factory for additional support.

9.2 Inaccurate or Missing Data If the data being read from the Smart RTU unit is either inaccurate or missing, this could have several causes:

Incorrect/loose cable connections

Unit configuration incorrect

Inaccurate sensor calibration

Incorrect receiver configuration

Sensors not installed correctly on equipment

9.2.1 Incorrect/Loose Cable Connections Ensure the sensor cables to the Smart RTU are in accordance with the wiring diagram supplied with the unit. Reconnect all sensor wires to ensure tight connections on wiring (ensure terminal blocks are not clamped down on insulation of wires).

9.2.2 Unit Configuration Incorrect If the inaccurate/missing data problem is across all sensors, reload the original configuration for the Smart RTU unit (see PSP user instructions).

9.2.3 Inaccurate Sensor Calibration If the data received on certain channels/sensors is not accurate, recalibrate those sensors (see PSP user instructions).

9.2.4 Incorrect Receiver Configuration Refer to receiver instructions to confirm correct configuration. If necessary, contact factory to reload receiver configuration settings. 9.2.5 Sensors Not Installed Correctly on Equipment Check physical installation of sensors on equipment being monitored.

9.3 No Data Recorded on VB-103-TAM If no data is being stored to the VB-103-TAM unit, this could have several causes:

Incorrect/loose sensor cable connections

Loose VB-103-TAM connection

Low battery on VB-103-TAM

Incorrect VB-103-TAM log interval

configuration

9.3.1 Incorrect/Loose Sensor Cable Connections Ensure the sensor cables to the Smart RTU are in accordance with the wiring diagram supplied with the unit. Reconnect all sensor wires to ensure tight connections on wiring (ensure terminal blocks are not clamped down on insulation of wires).

9.3.2 Loose VB-103-TAM Connection Ensure the VB-103-TAM and Smart RTU 6-pin amphenol style ports are free from dust and debris. Use compressed moisture free air to blow out any debris if needed. Disconnect and reconnect the VB-103-TAM from the Smart RTU unit. Ensure that VB-103-TAM is completely and fully threaded onto the Smart RTU 6-pin amphenol style connector (tighten VB-103-TAM onto amphenol style connector, push VB-103-TAM gently onto connector and then tighten further until it will go no further to ensure proper connection). 9.3.3 Low Battery on VB-103-TAM Check to see if VB-103-TAM unit can be read on an IPS Dock. If not, replace VB-103-TAM unit (the VB-103-TAM battery is not user replaceable). 9.3.4 Incorrect VB-103-TAM Log Interval Configuration Connect the VB-103-TAM to the IPS Dock and ensure the log interval is set to the expected value (see IPS Dock user instructions for additional details on how to perform this task).

9.4 No Lights on Lights or Display Accessories If no lights are flashing on the RTU-OVAL or RTU-SAL-X lights accessories or no data is shown on the RTU-SID-X display, this could have several causes:

Unit not powered up

Loose wiring connections

9.4.1 Unit Not Powered Up Verify battery and power supply/solar panel fuses are connected and not blown (refer to included wiring diagram for where these fuses are located). 1. Open the power supply/solar panel fuse. 2. Read battery level using voltmeter connected

to battery terminals. If the battery level is


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below 11V, replace the battery according to instructions in section 4 MAINTENANCE.

3. If communications are still not successful, confirm the power source being used to charge the battery. This procedure will vary depending on if your unit has a solar panel or AC power input.

a. AC Power: confirm the voltage coming out of the 24V power supply is close to 24VDC. If there is no output from the power supply, confirm that AC power is connected to the power supply. If the AC power connection is working, the power supply will need to be replaced. Contact the

Flowserve factory for assistance. b. Solar Panel: confirm the power

coming out of the power regulator is 12VDC or higher. If there is no output from the regulator, confirm that the solar panel is connected to the input and functional. If the solar panel supply is working, the voltage regulator will need to be replaced. Contact the Flowserve factory for assistance.

Figure 13: Measuring AC power supply output on Smart RTU using a voltmeter 9.4.2 Loose Wiring Connections Ensure the RTU-OVAL, RTU-SAL-X lights and RTU-SID-X display accessories are in accordance with the wiring diagram supplied with the unit. If none of the above solutions are successful in resolving the issue, contact the factory for additional support.


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10 DECLARATION OF CONFORMITY (TYPICAL) We, Flowserve Corporation

10920 West Sam Houston Parkway North Suite 950

Houston, Texas 77064 USA

Declare in sole responsibility that the equipment:

ELD-102-X Single Point Transmitters SELD-103-X Smart Point Transmitters

ELD-FA-403-Receiver, AO/DO and Serial Modbus S-EGI-NB-4/20-AC/SP, Smart RTU

ELD-FA-525-AC/SP, Intelligent Repeater

Including all options and versions of the base model numbers to which this Declaration refers are in compliance with the Directives and Norms specified herein. 1.1 EMC Directive 2004/108/EC Basis for compliance:

The equipment has been assessed using the following standards and is supported by the following technical documents:

EN 61326-1 2006 Electrical equipment for measurement, control and laboratory use - EMC requirements - Part 1: General Requirements

EN 55011 2009 Industrial, scientific and medical equipment. Radio-frequency disturbance characteristics. Limits and methods of measurement Class A, Group 1

EN 61000-3-2, EN 61000-3-3, EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6, EN 61000-4-8, EN 61000-4-11

Series, Electromagnetic compatibility (EMC).

Under these environmental and use conditions: Industrial Applications, Pollution Degree 2

Technical File Reference Number: 701-5000

Installation and use of this equipment shall comply with the relevant installation and use instructions. 1.2 Low Voltage Directive 2006/95/EC Basis for compliance:

The Single point transmitters are fully-enclosed, intrinsically-safe apparatus and are considered to meet the requirements as set forth in the standard below without further consideration:

EN 61010-1 2002 Safety requirements for electrical equipment for measurement, control and laboratory use. Part 1 General requirements

Under these environmental and use conditions: Industrial Applications, Pollution Degree 2


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Declaration of Conformity

1.3 ATEX Directive 94/9/EC + all amendments Basis for compliance:

The equipment has been assessed using the following standards and is supported by the following technical documents:

EN 60079-0 2006 (+ corr. 1)

Electrical apparatus for explosive gas atmospheres Part 0 General requirements

EN 60079-11 EN 60079-26

2007 2007

Explosive atmospheres Part 11 Equip protection by intrinsic safety i Explosive Atmospheres- Part 26: Equipment with equipment protection level (ELP) Ga

EN 61241-0 2006 Elec App for use in presence of combustible dust Part 0 Gen requirements

EN 61241-1 2004 (+ Corr. 1 & 2)

Elec app for use in presence of combustible dust Part1 Protection by enclosures tD

EN 61241-11 2005 Elec app for use in presence of combustible dust Part11 Protection by intrinsic safety iD

Certificate Number: Sira 10ATEX2013 Notified Body: Sira Certification Services, 0518 Report Number: R20441A Markings:

Notified Body: CSA International Report Number: 1005105 Markings:


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The technical documentation required to demonstrate that the product meets the requirements of the Directives has been compiled by the signatory below and is available for inspection by the relevant enforcement authorities. Signed: _____________________________________________ Date: _________________________ Authorized Person, Rick Lawson General Manager


Your Flowserve factory contacts: Flowserve Corporation 10920 W Sam Houston Parkway N, Suite 950 Houston, TX 77064 USA Phone: +1 832 375 0807

Your Flowserve sales contact: Go To: www.flowserve.com Equipment Monitoring and Control Products

FLOWSERVE REGIONAL SALES OFFICES:

USA and Canada

Flowserve Corporation

Pump

5215 North O’Connor Blvd.,

Suite 2300

Irving, Texas 75039-5421 USA

Telephone 1 972 443 6500

Fax 1 972 443 6800

Europe, Middle East, Africa

Flowserve FSG – Italy

Worthington S.r.l.

Via Rossini 90/92

20033 Desio (Milan), Italy

Telephone +39 0362 6121

Fax +39 0362 303 396

Latin America and Caribbean

Flowserve Corporation

6840 Wynnwood Lane

Houston, Texas 77008 USA

Telephone 1 713 803 4434

Fax 1 713 803 4497

Asia Pacific

Flowserve Pte. Ltd

10 Tuas Loop

Singapore 637345

Telephone 65 6771 1600

Fax 65 6779 4607

http://www.flowserve.com/

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