JP3 Measurement Verax VPA Installation Manual

Verax 75M and Verax VPA Installation Manual JP3 Measurement 4109 Todd Lane Austin TX 78744 512-537-8450 www.jp3measurement.com 03/31/2016 Verax 75M Installation Instructions, Rev 11 1 Table Of Contents: 1. Facilities Requirements page 3 2. Unpacking and Handling page 5 3. Mounting the Control Panel page 7 4. Wire Verax Control Panel to Mux Panel page 9 5. Mounting the Probe Assembly page 11 6. Probe Assembly to Control Panel Connections page 13 7. Z-purge installation (Optional) Page 20 8. Heater Blanket for Probes (Optional) Page 22 9. Power Up and Commissioning Page 23 03/31/2016 Verax 75M Installation Instructions, Rev 11 2 1) Facilities Requirements: Intended Use: The Verax 75M is an optical NIR analyzer for determining the constituents and physical properties of a hydrocarbon fluid stream by using NIR spectroscopy to model the parameter of interest. The 75M can monitor up to 10 read points with the same control panel. Contact a JP3 sales representative to discuss the range of analysis available. The Verax 75M-Z model incorporates a Z-purge system for mounting in a Class I / Division 2 location. Location Rating: • • • • • Verax 75M Analyzer is in two Type 4 NEMA Enclosure, and all provided fittings are Type 4 rated. For General Purpose Location, Conforms to ANSI/UL Std 610101 For Class I / Division 2 A,B,C,D, T Code- T4 a Type Zpressurization must be used. With Z-purge, Conforms to NFPA Std 496 Certified to CAN/CSA Std C22.2 No. 61010-1 Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F). Electrical Input Requirements: • • • Per Customer Specification one of the two options below: • 100-240V AC, 50-60 Hz, 1.6-0.7 Amp • Or, 24V DC, 3.5 Amp The input electrical configuration is indicated on the warning tag below the antenna on the left side of the box (see Figure 3) For surge protection a 20A breaker is recommended as the customer-provide disconnection device Other Facilities Requirements (for Z-purge only): • Instrument Air or Nitrogen • Supply pressure: 80-120 psig • Safe Pressure Set Point: 0.25’ water column • Safe pressure flow rate: 0.13-3.5 SCFH • Exchange Flow Rate: 4 SCFH 03/31/2016 Verax 75M Installation Instructions, Rev 11 3 Explanation of Warning Labels: The following warning applicable only when using the Z-purge option: WARNING – PRESSURIZED INCLOSURE This enclosure must not be opened unless the area atmosphere is known to be below the ignitable concentration of combustible materials or unless all the devices within have been de-energized AVERTISSEMENT : BOÎTIER SOUS PRESSION: Ce boîtier ne doit pas être ouvert à moins que l'atmosphère de la zone ne soit inférieure à la concentration inflammable de matières combustibles ou à moins que tous les dispositifs qui s’y trouvent n’aient été mis hors tension. The following warning applicable only when using the Z-purge option: WARNING: Power must not be restored after enclosure has been opened and until enclosure has been purged for 3.5 minutes for Verax 75-Z model or 6 minutes for Verax 75M-Z AVERTISSEMENT: L'alimentation ne doit pas être rétablie après l’ouverture du boîtier et jusqu'à ce que le boîtier ait été purgé pendant 3,5 minutes pour le modèle Verax 75-Z ou 6 minutes pour le modèle Verax 75M-Z. The following warning applicable to all models: The model and electrical configuration on the warning label are specified with punched holes next to the applicable value. Le modèle et la configuration électrique sur l'étiquette d'avertissement sont spécifiés avec des trous percés à côté de la valeur applicable Figure 1: Warning Label Located on the left side of the analyzer below the antenna port. (see Figure 3) 03/31/2016 Verax 75M Installation Instructions, Rev 11 4 2) Unpacking and Handling: Shipped Materials: • • • • • • Verax Analyzer Control Panel (qty 1) Mux Control Panel (qty 1) Probe Tree Assembly (one per analysis point) Fiber Optic Cable Pair (one pair per probe tree) Antenna (qty 1) Z-purge w/ fittings (optional, 1 set) 24” 18” Handling Instructions: • • • Verax Control Panel 31.25” • Weight: 51lbs • Dimensions: 24’’ x 30’’ x 9.35’’ • Mounting Holes: 18” x 31.25” Mux Control Panel • Weight: 40lbs • Dimensions: 24’’ x 24’’ x 9.35’’ • Mounting Holes: 18” x 25.25” 30” Verax Control Panel Uncrate and mount the Control Panels and mount to unistrut or other mounting surface capable of handling the weight of the unit. Do not drop. 24” 25.25” • The Mux Control Panel should be mounted no more than 12” below the Verax Control Panel • If using a Z-purge 12” between panels is required to make room for the purge panel. 12” Mux Control Panel Figure 2 – Verax 75M Analyzer Control Panel - Dimensions 03/31/2016 Verax 75M Installation Instructions, Rev 11 5 Antenna Fitting Serial # & Warning Label Wiring Terminal Blocks Radio / Modem Incoming Power Connection PLC Ethernet Switch (Comm) PC Transducer Terminal Blocks RTD Terminal Blocks Verax Control Panel PLC Expansion Modules Spectrometer Mux Control Panel Mux Terminal Blocks Multiplexer Figure 3 – Verax 75M Analyzer Control Panel – Front View 03/31/2016 Verax 75M Installation Instructions, Rev 11 6 3) Mounting the Control Panels: Mounting Requirements: • • • • • • Select a location that is easily accessible at grade level. Mounting holes are provided for easy installation. The Mux Control Panel must be mounted no more than 12” below the Verax Control Panel. When using a Z-purge 12” separation is required to make room for the purge panel on the Mux Control Panel (see Section 7 for details) Shade is required if mounting outdoors where ambient temps can exceed 90⁰ F. Do not mount the analyzer in such a way to make it difficult to operate the customerprovided electrical disconnect device (switch, breaker or other) Antenna Connection: 1. 2. 16dB Antenna is provided along with a 90 degree fitting. Attach Antenna to the fitting on the upper left of the Analyzer Panel using the 90 degree fitting (see Figure 3 for location of the fitting). Routing Fiber Optic Cable Between Probe Set and Mux Control Panel: Warning – Read Carefully • • • • Fiber optic cable is extremely sensitive to sharp bend angles and contamination. Handle very carefully to avoid kinks and keep the ends capped until ready to attach to the probes: Maintain a minimum 7” bend radius when running/routing the fiber from control box to probe assembly It is recommended that the fiber optic cable be run in its own dedicated conduit. Do not place fiber in open cable trays where it can be stepped upon. Keep the fiber ends capped until you a are ready to connect 03/31/2016 Verax 75M Installation Instructions, Rev 11 7 Pass-through for Electrical Wires: • The Verax Control Panel is shipped without holes or wire ways for most of the incoming electrical service or fiber connections. The only pre-positioned holes are: • The Antenna fitting (top left of the Verax Control Panel), • The wire pass-throughs between the Verax and Mux Control Panels (bottom left for the top panel, top left for the mux panel). • Additional wire pass-throughs will need to be installed by the customer. The placement of these holes is left up to the customer’s installation teams in order to provide maximum flexibility to bring the cables and fiber from below or above, and attach them to the Verax Control Panels with a sufficient size conduit or fitting. • All connections or fittings chosen by the customer should by rated for Type 4 enclosure. • After the wires and fibers are run, all ports and pass-throughs must be plugged with duct putty or some other standard industry practice to assure the sealed integrity of the enclosure. • The customer must plan for the following cables when choosing the size and placement of ports on the Verax Control Panel: • One Incoming Electrical Cable to the Top Verax Panel • One Incoming communications Cable to the Top Verax Panel • One RTD cable from each probe set to the Top Verax Panel • One Transducer cable from each probe set to the Top Verax Panel • Two Optical Fibers (send and receive) from each probe set to the Bottom Mux Panel. • Read instructions in Section 6 regarding where these fibers/cables attach inside the control panels before you start cutting holes. • The customer is responsible to protect the inside of the control panel when cutting or punching holes for the wire way. DO NOT ALLOW METAL SHAVINGS TO FALL ON THE ELECTRICAL CONNECTIONS OR COMPONENTS INSIDE THE CONTROL PANEL. • Contact your local JP3 sales representative to discuss options 03/31/2016 Verax 75M Installation Instructions, Rev 11 8 4) Wire the Verax Control Panel to the Mux Control Panel: Connect 4 wires from Verax to Mux Control Panels: 1. 2. 3. 4. The Verax 75M is shipped with 4 cables coiled in the Verax Control Panel that need to pass through the flex conduit to the lower Mux control Panel. These are labeled: • Mux Power Cord (2-wire cable) • Spect Power Cord (2-wire cable) • Mux Comm Cable (3-wire cable) • USB Cable Install the provided ½” and ¾” flex conduit between the liquid tight fittings on Mux and Verax Panels. Pass the wires through the flex conduit as shown in Figure 4. Connect the cables to the Mux Wire Terminal Block as shown in Figure 4. Mux Power and Spect Power Mux Comm and USB Mux Wire Terminal Block Figure 4 – Mux Power/Comm/Ground Wiring Schematic 03/31/2016 Verax 75M Installation Instructions, Rev 11 9 Connect the USB: 1. Attach The USB cable to the back of the spectrometer, under the spectrometer cover as shown in Figure 5. The cover does not need to removed to make the attachment. USB port Figure 5 – USB plug for spectrometer 03/31/2016 Verax 75M Installation Instructions, Rev 11 10 5) Mounting the Probe Assembly: Placement: • • The Probe Assembly are typically mounted to a unistrut frame, or other solid structure Probes should be accessible at grade level. Pressure and Temp Rating: • • All probe windows and probe assemblies are tested to 1500 psi Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F). Bypass Probe Configuration: • • • • • • For a bypass probe assembly, the customer taps into the process stream they want to monitor, plumbs the fluid to the inlet on probe assembly, and back to the process stream. (see Figure 4 on the next page) It is highly recommended that the customer supply a stinger at the inlet and return of the pipe you are monitoring in order to pull fluid from the center of the pipe. Either ½” or ¼” Swagelok fittings are supplied on the inlet and return ports of the probe assembly. Customer supplies ¼” or ½” stainless steel tubing as dictated by the fittings supplied on the probe assembly. • ½” is typical for liquids • ¼” is typical for gas The customer must assure sufficient flow of liquid or gas over the probe windows by providing a pressure drop of at least 1 PSI from inlet to outlet. Choosing the correct inlet and return points on the process pipe is critical to assure flow. Often choosing inlet and return points such that flanges, valves, meters or similar instruments are located between these points is sufficient to provide the necessary bypass pressure differential. Actual Installation details vary by location and application; consult with JP3 Sales representative to discuss options. When using a heater blanket with the probe assembly, 120VAC, 2 Amp service is required. The junction box must be within 4 feet of the probe assembly. 03/31/2016 Verax 75M Installation Instructions, Rev 11 11 Min ∆P from Inlet to Return = 1 psi Return Inlet Figure 5 – Example Probe Bypass Arrangement 3-way Return Valve Receive Fiber Fittings Transducer Service Port DO NOT REMOVE CAP RTD Stinger at the inlet to sample from center of the pipe Service Port DO NOT REOME CAP Send Fiber Fittings Conduit Housing Inlet Port Top-Down View Figure 6 – Bypass Probe Assembly 03/31/2016 Verax 75M Installation Instructions, Rev 11 12 6) Probe Assembly to Control Panel Connections: Connect Fiber Optics to Probe Assembly: Warning – Read Carefully • • • • Fiber optic cable is extremely sensitive to sharp bend angles and contamination. Handle very carefully to avoid kinks and keep the ends capped until ready to attach to the probes: Maintain a minimum 7” bend radius when running/routing the fiber from control box to probe assembly It is recommended that the fiber optic cable be run in it’s own dedicated conduit. Do not place fiber in open cable trays where it can be stepped upon. Keep the fiber ends capped until you a are ready to connect Attach Fiber to Probe Assembly: 1. 2. 3. 4. 5. Open the conduit housing on the probe assembly Install the fiber using LT50 fittings and flex conduit at either end of the probe assembly (see Figure 6). The flex conduit approach offers the best protection for the fiber. Connect the fiber to the back of the probe inside the conduit housing by screwing the fiber end onto the threaded probe connection. (see Figure 7) DO NOT THROW AWAY THE KNURLED CAPS. These should be left in the conduit housing to be used to protect fiber and probe connections when disconnected during servicing. Replace conduit housing cover Liquid Tight Fitting Figure 7 – Fiber Installation on Probe Assembly 03/31/2016 Verax 75M Installation Instructions, Rev 11 Fiber/Probe Connection Point 13 JP3 Measurement Fiber Optic Cable Specification JP3 uses a custom optical fiber assembly, design and characterized to maximize the characteristics of the optical loop from laser to probe and back to the detector. The following are specifications important for handling and installation of the fiber: • 600um-core multimode fiber with a Kevlar jacket. • 5.5mm black PVC weather proof furcation jacket, UV resistant • Outdoor rated construction, and all components nonconductive  (most similar to OFNR indoor construction) • Weight = 22 lbs/1000 feet (3.3kg/100m) • Max Installation Tension, 180 lbs (800N) • Max Operating Tension, 90 lbs (400N) • Installation Temp Range, 15⁰ F to 176⁰ F (-9C to 80C) • Operational temp range, -40⁰ F to 122⁰ F (-40C to 50C) • Minimum Bend Radius = 7” (18cm) • Male SMA connections on both ends. • Each end will be labeled as below: Figure 8 – Fiber Assembly dimensions and labeling 03/31/2016 Verax 75M Installation Instructions, Rev 11 14 Attach Fiber Optics to Mux Control Panel: 1. 2. 3. 4. 5. 6. 7. Two Optical Fiber from each probe assembly are connected to the Multiplexer in Mux Control Panel. Pass the fibers into the Mux Control Panel through customer-provided pass-through. Send Fibers are connected to the to the right face of the Multiplexer, receive fibers are connected to the left side of the Multiplexer Each analysis or measurement point is assigned a number 1-10. The connections are numbered on the Multiplexer face. Send fibers from number 1 should be paired with the receive fiber from number 1, number 2 to number 2, and so on. Connect the send fibers to the right face by screwing the SMA connector to the threaded connection on the Multiplexer. The SEND fibers will be labeled “SEND” using 2” Red Shrink Tube at both ends. Connect the receive fiber to the left face by screwing the SMA connector to the threaded connector on the Multiplexer. The receive fibers will be labeled “RECEIVE” using 2” Yellow Shrink Tube label at both ends. DO NOT THROW AWAY KNURLED CAPS FROM THE FIBER OR THE Multiplexer. These are needed to protect the connections during servicing. A box for storage of the caps is provided in the bottom of the Mux Control Panel. Receive Fiber Connections Send Fiber Connections analysis points are numbered 1-10 Multiplexer Figure 9 – Fiber Connections to the Multiplexer in the bottom of the Mux Control Panel 03/31/2016 Verax 75M Installation Instructions, Rev 11 Center Port Fiber goes to the spectrometer (already connected) 15 Wire the Probe Assembly to the Verax Control Panel: Attach RTD Cable to Control Panel 1. 2. 3. 4. At the probe assembly connect the RTD wires to the customer provided electrical cable. At the Verax Control Panel run the RTD cables through customer-provide wire pass through port (see section 3) and route to the terminal blocks on the left side of the panel. Each analysis point is assigned a number (the same number assigned to the fiber from that analysis point), and the terminal blocks are labeled numbers 1-10 Connect the RTD cable from number 1 to the terminal block for number 1 as in Figure 10. Continue likewise with subsequent numbers. • one red wire to the top terminal tier • the other red wire to the middle terminal tier • the white wire to the bottom terminal tier Figure 10 – RTD and Transducer Wiring Instructions 03/31/2016 Verax 75M Installation Instructions, Rev 11 16 Attach Transducer Cable to Verax Control Panel 1. 2. 3. 4. At the probe assembly connect the Transducer wires to the customer provided electrical cable. At the Verax Control Panel run the Transducer cables through customer-provide wire pass through port (see section 3) and route to the terminal blocks on the right side of the panel. Each analysis point is assigned a number, and the terminal blocks are labeled numbers 1-10 Connect the Transducer cable from number 1 to the terminal block for number 1 as in Figure 11. Continue likewise with subsequent numbers. • Red wire on the top terminal tier • Black on the second terminal tier • Brown on the third terminal tier • Gray on the bottom terminal tier Figure 11 – RTD and Transducer Wiring Instructions 03/31/2016 Verax 75M Installation Instructions, Rev 11 17 Connect the Ethernet Communications Cable to Verax Control Panel: 1. 2. Run the Ethernet communications cable through customer-provide wire pass through port and route to the Ethernet switch on the right side of the analyzer control panel. ( See Figure 3) Connect to any available Ethernet port Connect Main Power to Verax Control Panel: For 24V DC Power Configuration 1. Run the power cable through customer-provide wire pass through port and route to the terminal blocks on the upper right side of the analyzer control panel. ( See Figure 3) 2. Connect hot wire to 24V fuse 3. Connect neutral wire to 0V terminal Figure 12 – Main 24VDC Power Wiring Instructions 03/31/2016 Verax 75M Installation Instructions, Rev 11 Components shown inside dotted line only included with100-240V AC option 18 For 100-24VAC Power Configuration 1. Run the power cable through customer-provide wire pass through port and route to the terminal blocks on the upper right side of the analyzer control panel. ( See Figure 3) 2. Connect hot wire to 100-240V fuse 3. Connect neutral wire to 0V terminal 4. Connect ground wire to the green/yellow ground terminal Figure 13 – Main 100-240VAC Power Wiring Instructions 03/31/2016 Components shown inside dotted line only included with100-240VAC input option Verax 75M Installation Instructions, Rev 11 19 7) Z-Purge Installation (optional): Warning – Read Carefully • • You must install the Z-purge if the Verax 75M will be in a Class I / Division 2 Hazardous location. Consult Pepperl-Fuchs website to confirm the below arrangement for panel, pluming, and blow-off valve given specific conditions for your plant. Installation: • Mounting Configuration and Pipe Routing are shown below in Figures 14 and 15. All fittings are ¼” Figure 14 – Pipe Fitting Schematic, (Viewed from back of Mux Control Panel) 03/31/2016 Verax 75M Installation Instructions, Rev 11 20 Figure 15 – Z-Purge Hardware Configuration 03/31/2016 Verax 75M Installation Instructions, Rev 11 21 7) Probe Heater Blanket (optional): Installation: • Heater blankets are designed to wrap around the sample cell cross to keep the probes warm and free of paraffins. Electrical: • • • Heater blankets use Thermon self-regulating 12W/ft heating tape 2Amp, 120V AC electrical service A 5’ pigtail is provided using ½” flex conduit. Figure 16 – Heater Blanket 03/31/2016 Verax 75M Installation Instructions, Rev 11 22 8) Power-up and Commissioning: Power Up Sequence: • To Engage Power engage the fuses in the following order 1. 100-240V fuse (if applicable – for AC configuration only) 2. 24V fuse (Powers PLC Modules, Switch, and Multiplexer) 3. 12V (Powers PC and Radio) 4. Last 12V fuse (Pwers Spectrometer) Figure 17 – Power up sequence 4th 3rd 2nd 1st • At this point the Verax 75M Analyzer is ready to be commissioned. Contact JP3 Field Service team to complete installation and commissioning. • Contact JP3 Field Service team for all maintenance and servicing needs • service@jp3measurement.com • 512-537-8450 03/31/2016 Verax 75M Installation Instructions, Rev 11 23