CD52 BANDIT USER MANUAL CSA-UL 15 MAR 2016 BANDIT USER MANUAL... · CD52 Bandit (CSA-UL Cer ﬁ ca on) User Guide Page 3 of 44 WARNING Any opera on involving work on pipelines containing

1801 North Juniper AvenueBroken Arrow, Oklahoma 74012 U.S.A.+1 (918) 258–6068 worldwide

[email protected]

CD52 BanditNon-Intrusive Pig Passage Signaler(CSA–UL Cer fi ca on)

USER GUIDE

SA–UL Cer fi ca on)

SEER GUIDE

CD52 Bandit (CSA-UL Cer fi ca on) User Guide

Page 2 of 44

Informa on in this document is subject to change without no ce and applies only to the version of so ware, hardware or fi rmware described on the tle page.

The so ware, hardware and fi rmware described in this document are designed, manufactured and wri en by CDI. The so ware and fi rmware © 1999–2010 CDI with all rights reserved.

The CD52 product is covered under United States Patent No. 6,489,771 B1

The TRAXALL family of transmi ers is covered under United States Patent No. 9172406.

This document © 1999, 2016 CDI. All rights reserved.Document Number 89–03–0067–00 Revision 15 Mar 2016

Page 2 of 44

vision 15 Mar 2016on 15 Mar 2016

CAUTION: PRODUCT SHALL NOT BE USED WHERE THE ATMOSPHERES INCLUDE METHANOL AND ACETIC ACID.WARNING: ENCLOSURE SHALL NOT BE OPENED UNLESS THE AREA IS KNOWN TO BE NON-HAZARDOUS, OR UNLESS ALL DEVICES WITHIN THE ENCLOSURE HAVE BEEN DE-ENERGIZED.WARNING: EXPLOSION HAZARD - BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON- HAZARDOUS.WARNING: BATTERY OPERATION ONLY ALLOWED TO MAXIMUM 45° C.

MODEL: CD52 PIG PASSAGE SIGNALERINPUT RATINGS: 24VDC, 0.028A (28mA); 0.97 Watts – 24VDC 1.5V, 0.0018A (1.8mA); 0.0027 Watts – BatteryCLASSIFICATION: Class I, Div 1, Groups C & D, T6, Type 4 Tamb -50°C to +80°C (24VDC) Class 1, Division 1, Groups C&D, T6, Type 4 Tamb -50°C to +45°C (Battery)

S/N:

MFGR: CONTROL DEVICES INC. 1801 N. JUNIPER AVENUE BROKEN ARROW, OKLAHOMA, U.S.A. 74012 +1 (918) 258-6098 WWW.PIGGING.COM


Page 3 of 44

WARNING

Any opera on involving work on pipelines containing gases or liquids under pressure is poten ally hazardous. It is necessary, therefore, to follow correct procedures in the use of this equipment to maintain a safe working environment.

No person should use this equipment unless fully aware of poten al hazards of working with pressurized pipelines and trained in the procedures stated in this manual.

The purchaser of this equipment is responsible for the training and competence of operators and the manner in which it is used.

Contact CDI immediately should any diffi culty arise in the use of this equipment.

WARNING

Always use cau on when opening any CDI transmi er that has been in a pressurized environment.

It is possible for pressurized liquid or gas to leak into a transmi er and remain there even a er the transmi er has been removed from the pipeline.

Always point the transmi er away from yourself or others when opening a cover or end cap.


Page 4 of 44


Page 5 of 44

CONTENTS

INTRODUCTION ..................................................................................6

SETUP & OPERATION ..........................................................................7 Power Op ons ....................................................................................7 Power Confi gura on Chart .................................................................8 Ba ery Installa on .............................................................................9 User Board Jumper Se ngs .............................................................10 24 VDC & SCADA Connec ons ..........................................................12 Detec on Methods ...........................................................................15 User Interface ...................................................................................18

INSTALLATION ...................................................................................27 Standard and Stainless Steel Units ...................................................27 Armored Flex Cable Units .................................................................31

OPTIONAL EQUIPMENT ...................................................................32 Remote Indicator System (RIS) .........................................................32 Cathodic Protec on Base Moun ng ................................................32 Heater ...............................................................................................32 Heat Risers ........................................................................................32 Sunshade ..........................................................................................32 LineStat .............................................................................................33 TRAXALL 720/770 Pig Loca on & Tracking System ...........................33

WARRANTY ........................................................................................34

SERVICE & MAINTENANCE ...............................................................35

GENERAL ARRANGEMENT DRAWINGS ...........................................36

SYSTEM SPECIFICATIONS .................................................................41

PIG MAGNET MOUNTING ................................................................43

ABOUT CDI ........................................................................................44


Page 6 of 44

INTRODUCTION

*Contact CDI for customer-specifi ed length**CD52 Portable models are ba ery powered only and have no junc on box

INTRODUCTION

The CD52 Bandit is a computerized electronic device for non-intrusive detec on of pipeline pigs equipped with either a permanent magnet or 22 Hz electromagne c transmi er.

The Bandit accomplishes this by a proprietary and patented magne c fi eld antenna array located in its base and a ached to (or near) the pipeline. This antenna array signals an on-board computer if and when a pig passage has occurred.

When a pig passage is detected, the me and date of passage are recorded into the on-board memory of the Bandit and displayed on an LCD screen.

In addi on to the most recent pig passage me and date, the Bandit remembers the dates and mes of the previous nine pig passages as well. An operator may quickly and easily retrieve the dates and mes of the 10 most recent pig passages via the Bandit’s user interface.

The CD52 Bandit is available in several confi gura ons:

• Rigid stalk extension-mounted (“standard”) • Extended fl ex-cable* • Extended pipe* • Portable**

COMPUTER & DISPLAY

24 VDC& SCADA

JUNCTION

BASE & ANTENNA

STANDARD


Page 7 of 44

SETUP & OPERATION

SETUP & OPERATION

Power Op ons

The Bandit in its standard confi gura on can be powered for one year on two new D-Cell alkaline ba eries (see note). However, many customers choose to power the Bandit by supplying 24 VDC power.

In extreme cold temperatures, 24 VDC will be necessary to power the Bandit as a small hea ng element op on (see pg. 32) is required. Also, CSA–UL guidelines require use of external 24 VDC power where temperatures exceed +45°C.

See the Power Confi gura on chart on the following page to determine which power op on is required for your condi ons.

NOTE: If using ba eries as a power source, DURACELL® PROCELL (PC1300)

D-Cell alkaline ba eries are required by CSA–UL standards to maintain system cer fi ca on.

WARNING:Always remove ba eries before placing the unit into storage

and/or confi guring for 24 VDC opera on. Failure to do so may result in damage and may void warranty.

EXTENDED PIPE

FLEX CABLE

PORTABLE


Page 8 of 44

SETUP & OPERATION

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Page 9 of 44

SETUP & OPERATION

Ba ery Installa on

To install D-cell ba eries:

1. Unscrew and carefully remove front cover

2. If old ba eries are in place, pull cable- e release tab (use small screwdriver or fi ngernail) to disengage cable- e.

3. Insert new alkaline ba eries,both with posi ve (+) side up.

NOTE: The ba ery cable es are releasable. Do not cut them.


Page 10 of 44

SETUP & OPERATION

User Board Jumper Se ngs

The CD52 Bandit user board contains a jumper block which has been factory set for ba ery or 24 VDC power source, depending on specifi ca on at me of order. If power source is to be changed (for example, if your CD52 was ordered and shipped as a 24 VDC-powered unit and you desire instead to operate it with ba eries), you must re-set the jumper as shown:

Board Se ngs for Ba ery Power

Set jumper to Pin 1.

NOTE: Set jumper before installing ba eries.


Page 11 of 44

SETUP & OPERATION

Board Se ngs for 24 VDC Power

Set jumper to Pin 2.

CSA–UL WARNINGS

Tamb = –30°C ~ +80°C (24 VDC OPERATION)Tamb = –20°C ~ +54°C (BATTERY OPERATION)

WARNING: USE ONLY DURACELL PC1300 BATTERIESWARNING: DO NOT MIX OLD WITH NEW BATTERIESWARNING: DO NOT OPEN WHEN ENERGIZEDWARNING: EXPLOSION HAZARD – BATTERIES MUST ONLY BE CHANGED IN AN AREA KNOWN TO BE NON-HAZARDOUSWARNING: BATTERY OPERATION ONLY ALLOWED TO MAXIMUM 45°CWARNING: DO NOT OPEN WHEN AN EXPLOSIVE GAS ATMOSPHERE

IS PRESENT


Page 12 of 44

SETUP & OPERATION

24 VDC & SCADA Connec ons

It is the customer’s responsibility to provide their own wiring and conduit for 24 VDC power and SCADA. To route 24 VDC and SCADA into the Bandit unit:

1. Remove the Killark junc on box side plug.

* SCADA (Supervisory Control and Data Acquisi on) compa ble relay contacts can be used for passage annuncia on (lights, horns, etc.) where an unmanned passage must be monitored.

n box side plug.

SCADA (S i C t l d D t A i i ) bl l


Page 13 of 44

SETUP & OPERATION

2. Remove the junc on box faceplate, feed the wiring through the conduit and using the wiring diagram (following page), secure the wires to the proper terminals.

3. Replace the junc on box cover and secure by hand- ghtening.

At this point, with correct electrical connec ons, you should have an assembled and fully-func onal CD52 Bandit system. A system wired in this manner is capable of running on 24 VDC (allowable range: 21.6 to 26.4 VDC) and indica ng a passage to the SCADA system via relay closure.

NOTE: Once plugs are removed–and wiring installed–it is cri cal that the holes be resealed properly for the Bandit to remain

water ght. This can be done with pipe dope or pipe sealant and a proper conduit pipe.

It is the customer’s responsibility to ensure that all conduit connec ons are made and sealed according to CSA–UL standards to maintain system cer fi ca on.


Page 14 of 44

SETUP & OPERATION


Page 15 of 44

SETUP & OPERATION

Detec on Methods

The CD52 Bandit detects pig passages via two very dis nct methods: permanent magnets and 22 Hz electromagne c transmi ers. The advantages to each method are discussed below.

Permanent Magnets

The Bandit will detect rare earth permanent magnets a ached to a pipeline pig. Magnets for this purpose are sold by CDI and are available for pipelines from 2 in. to 60 in. [50.8 mm to 1524 mm].

Page 15 of 44

NOTE: Where pipe wall thickness exceeds 25.4 mm [1 in.], a custom

magnet design may be required. Please consult CDI for an evalua on of deployment op ons.

38.101.500

PART #81-02-0007-00

PART #81-02-0006-00

1.26032

292.1011.500

THREAD

MAGNET FOR PIPES 32" THRU 48"CD52 M3 MAGNET

1/2-13

NUT

of DWG-CD52-20031

FOR CD52 PIG DETECTION SYSTEM

CD52\Magnets\TOP ASSEMBLY B

SCALE:

BSIZE REV

PERMANENT MAGNET ASSORTMENT

DWG NO.SHT

REVISIONSREV DESCRIPTION DATE APPROVAL

ENGR1

PART NO.NOTED

RareEarth SET 2004N/A: FILE:

2

TOLERANCE.XXX = .015.XX = .03.X = .06ANGLE =

#

REVISED M1, M2 & M3

A F. WHITE2/17/00

10/21/04CHANGED DIA DIM 1.345 WAS 1.315

F. WHITE

ADDED DECAL WITH PART NUMBER

B

34.931.375

4. MOUNTING STUDS ARE STAINLESS STEEL.

CD52 M2 MAGNET

6.250158.75

33.661.325

14" THRU 30"MAGNET FOR PIPES

THREAD1/2-13

NOTES:1. MAGNETS ARE HIGH STRENGTH RARE EARTH PERMANENT MAGNETS.2. MAGNETS M1 AND M2 ARE POTTED INTO PVC OUTER SHELL, M3 IS POTTED INTO ALUMINUM.3. DIMENSIONS ARE IN INCHES AND [MM].

NUT

34.931.375

CD52 M1 MAGNET

PART #81-02-0005-00

2.25057.15

33.66

MAGNET FOR PIPES UP TO 12"

1.325

THREAD1/2-13

NUT


Page 16 of 44

SETUP & OPERATION

Advantages of Permanent Magnets

• Small • Inexpensive • Low maintenance • Ba eries are not required

Despite these benefi ts, because of the permanent magnet’s sta c magne c fi eld, it may be diffi cult to locate a pig that is stalled, obstructed, or otherwise immobilized in a pipeline. In these situa ons, an ac ve (electromagne c) transmi er is a recommended op on.

Electromagne c Transmi ers

The CD52 Bandit detects ac ve electromagne c transmi ers. CDI off ers the largest family of pipeline pig loca on and tracking transmi ers in the industry.

Our Transmi ers operate by emi ng electromagne c fi elds at a very low frequency (between 15 and 30 Hz). This makes CDI’s pig tracking transmi ers safe and reliable for use in any onshore or off shore environment and any pipeline product (water, oil, gas, ammonia, carbon dioxide, etc.).

Many models even have the ability to remain dormant un l ac vated by preconfi gured pipeline pressure.


Page 17 of 44

SETUP & OPERATION

Another advantage of CDI’s ac ve transmi ers is the ease of loca ng an immobilized pig. A stuck pig can easily be detected by walking the pipeline from the last known loca on using a handheld ac ve locater system.

With that in mind, CDI is proud to off er our customers the TRAXALL Mul -source Pig Loca on and Tracking System.

(See pg. 33 for details for more informa on about the TRAXALL.)

It is possible to use both a permanent magnet and a transmi er in the same pig. This will not prevent the Bandit, TRAXALL, or CD42 Receiver systems from successfully tracking and loca ng pigs.

Regardless of which type of transmission source you use, the Bandit will detect it.

Advantages of Electromagne c Transmi ers

• Easily located with a handheld device • Quicker to locate

to off er l -source m.

.)

event the ver systems from

ng pigs.


Page 18 of 44

SETUP & OPERATION

The User Interface

The Bandit’s user interface display contains much informa on for an operator, yet is quite simple and easy to read.

This display automa cally cycles between showing the most recent pig passage me, date and the actual real- me every seven (7) seconds. This allows the operator to approach the Bandit on site and see the most recent pig passage me and verify the internal clock is set correctly – all without touching the unit.

Passage Time / Current Time

These display segments normally alternate between showing the most recent pig passage and the actual real- me as known by the unit. When the real- me

is displayed, the colon will blink (momentarily appear) and the “TIME” Ac ve Func on Indicator segment will display.

When the most recent pig passage me is displayed, the colon display will be constant (non-blinking) and the “TIME” Ac ve Func on Indicator segment will not display.

Passage Date / Current Date

These segments normally alternate between displaying the real- me date and the date of the most recent pig passage. This date is in American format (MONTH–DATE;

the year is not displayed). Therefore, 4–05 would be April 5th, with the year assumed to be current year.

ACTIVEFUNCTION

INDICATORSPASSAGE DATE/CURRENT DATE

PASSAGEINDICATORMARKED

RECENTPASSAGE

INDICATOR

PASSAGE TIME/CURRENT TIME


Page 19 of 44

SETUP & OPERATION

Recent Passage Indicator

The Recent Passage Indicator segment at the lower half of the Bandit’s display area indicates that a pig passage has been recently

detected. The behavior of this segment conveys informa on about how recently the pig passage occurred.

When a pig passage occurs, the segment will blink once per second for one full hour a er the pig passage. A er one hour, the display will switch to a constant-on mode. This feature allows an operator to quickly determine how recently a pig has passed.

Therefore, a constant-on segment indicates a pig passage has occurred within the last 12 hours but more than one hour ago.

RECENT PASSAGE SEGMENT STATUS

MEANING

SEGMENT NOT LITNo passage detected

within the last 12 hours

SEGMENT BLINKINGPassage was detected

within the last one hour

SEGMENT LIT, NOT BLINKING

Passage was detected more than one hour ago,

but less than 12 hours ago

Displayed Passage Indicator

The Displayed Passage Indicator is a cone-shaped array of 10 segments. Each one of these individual segments represents one of the 10 pig passage mes

that are recorded in the Bandit’s memory. The larger the segment, the more recent the pig passage is represented.

d d h b h


Page 20 of 44

SETUP & OPERATION

Ac ve Func on Indicators

The Ac ve Func on Indicators are an array of 10 rectangular LCD segments aligned ver cally along the le -hand side of the display.

* Suspend Mode feature is available only on the portable

Bandit (see pg. 26). When in Suspend Mode the

Ac ve Func on Indicator LCD will cycle between

F1 and F2 every second.

Note: some of the segments are

reserved for future func ons and/or

customer-requested applica ons.

F1 Unit is in Suspend Mode*

F2 Unit is in Suspend Mode*

F3 Reserved

F4 Reserved

RELAY Internal contact relay engaged

F6 Reserved

F7 Reserved

F8 Reserved

TIME Real- me currently displayed

BTN User Interface Lever currently engaged

e display. p


Page 21 of 44

SETUP & OPERATION

Display Rota on

During normal opera on the Bandit automa cally cycles between two display screens. The fi rst screen shows me and date of the most recent pig passage. The second screen is the current (real) me.

For example: If a Bandit unit records its most recent pig passage at 3:35 PM on July 16, and the real me is 5:20 PM, the operator will see two displays alterna ng every seven seconds as shown here:

MOST-RECENTPIG PASSAGEMARKED

REAL TIMEDISPLAYED

SECONDS7

TIMEINDICATOR

MARKED

SECONDS7

Interface Lever

The pivo ng lever on the side of the unit has several func ons:

• Retrieving dates/ mes of the last ten passages • Clearing the recent passage indicator • Set the real- me clock

The lever contains a small magnet that actuates a reed switch. Rota ng this lever controls all aspects of the Bandit’s user interface. In its neutral (disengaged) posi on, the red lever hangs down. To ac vate, rotate the bo om of the lever away from you.


Page 22 of 44

SETUP & OPERATION

Any me the Bandit’s lever is ac vated, the “BTN” display segment will confi rm contact.

To ensure Bandit’s availability under adverse condi ons (wind, icing, vandalism, etc.) that could move the lever into the engaged posi on while una ended, the unit will automa cally override the lever se ng a er one minute and 45 seconds, and automa cally return to normal opera on.

Real- me Display

The primary purpose of the real- me display is to allow an operator to quickly and easily confi rm the clock is set to the correct me. (See page 24 for instruc ons on se ng the clock.)

The real- me display has the following characteris cs:

NO PASSAGEINDICATORS MARKED

BLINKINGTIME DISPLAY

COLON

TIMEINDICATOR

MARKED


Page 23 of 44

SETUP & OPERATION

Most Recent Pig Passage Display

Pig passages are captured and indicated on the display of the Bandit. Typically, the operator is interested in the me and date of the most recent passage. By default the Bandit displays this informa on. Anyone can approach a unit and see the most recent passage data without interac on.

When displaying the me of the most recent passage, the display will appear as shown:

MOST-RECENTPIG PASSAGETIME DISPLAY COLON

STEADY – DOES NOT BLINK

ACTIVEFUNCTION

INDICATORSUNMARKED

Previous Pig Passages

Use the Interface lever to review pig passage dates and mes other than the most recent. Simply rotate the bo om of the lever away from you and toward the rear of the unit.

Hold the handle in this posi on un l you no ce the BTN LCD segment marked as shown.


Page 24 of 44

SETUP & OPERATION

The display will change showing the second most recent pig passage with the date and me. The 10 bars represent pig passages. The largest bar represents the most recent passage.The smallest bar represents the oldest pig passage stored in memory.

A er one lever press, the screen should appear as shown here.

This display indicates that the second most-recent pig passage occurred at 10:16 AM on December 14th.

Repeatedly pressing and releasing the lever will toggle through the recorded pig passages and change the Displayed Passage Indicator segment to the corresponding indicator. Moving to the oldest passage in memory requires a total of nine (9) lever ac va ons, a er which the Displayed Passage Indicator segments loop back to the fi rst passage.

To exit this mode and return to the normal opera ng mode of cycling between the most recent passage me and the real (current) me, simply allow the lever to hang in its disengaged posi on for a period of twenty-fi ve (25) seconds. Normal display cycling will resume.

AM

epresents theag

n

6 A

presents the ge.

AM

SECOND-TO LASTPASSAGE INDICATORMARKED


Page 25 of 44

SETUP & OPERATION

Clearing the “Recent Passage” Flag

The Recent Passage LCD segment will blink for one hour a er a pig passage then remain on for an addi onal 11 hours. However,

you may wish to manually terminate the blinking cycle (for example, when the Bandit is used in a portable applica on or on a launcher or receiver). To clear the recent passage display, rotate the Interface Lever into the “ac vated” posi on (see pg. 21) and hold it there for a period of four (4) seconds. Once cleared, release the lever to return the unit to normal opera on.

Removing the “Recent Passage” message from the screen will not aff ect anything in memory. The most recent pig passage me and date will cycle every few seconds.

Se ng the Clock

Occasionally it will be necessary to set the unit’s real- me clock (see note.) To do so, hold the lever in the ac vate posi on for a period of eight (8) seconds. A er eight seconds you will see the majority of the Bandit’s display go blank. Release the lever, and then briefl y press and release it one me. You should then see a display similar to this:

NOTE: the unit calendar does

not automa cally compensate for a leap year, so it will be necessary to re-set the unit every February 29 to ensure accuracy.


Page 26 of 44

SETUP & OPERATION

The Bandit is now prepared to set the hour por on of the clock. To change the hour, simply rotate the lever to the ac vate posi on and hold it there. You should no ce the BTN segment lights and the hour digits begins to increase at a rate of one hour per second.

Con nuing to hold the lever in the ac vated posi on will cause the hours to increase un l they reach “12”, and then wrap to “1” (The Bandit uses 12-hour, not 24-hour me).

Hold the lever in the ac vated posi on un l the digit reaches the desired hour and then release. The display will jump to the minute por on of the me to set. The same method is used to set the minutes. Simply press and hold the lever to increment the digits, and release to move to the date.

Repeatedly pressing and releasing the lever while in clock set mode causes the unit to cycle through the following clock set op ons:

To end the clock set mode, simply release the lever. Normal Bandit opera on will return in twenty-fi ve (25) seconds andthe clock will be set to the me indicated.

Portable Models

The portable Bandit is designed for temporary loca on/reloca on from one tracking site to the next. It is iden cal to standard units in func on and opera on, with two notable excep ons:

• Ba ery power only • Suspend Mode push bu on

The Suspend Mode bu on is located on the back.When pressed, all Bandit func ons are paused to prevent inadvertent triggering of the unit during reposi oning. The Ac ve Func on Indicator LCD (pg. 20) will alternate between F1 and F2 every second.

1. HOURS

2. MINUTES

3. AM/PM

4. DAY

5. MONTH

cal to standard units in func on ons:

n tp

nit during

the back.aused to t during


Page 27 of 44

INSTALLATION

INSTALLATION

Standard Units

The Bandit can be installed on pig launchers, receivers, and all pipelines from 50.8 mm to 1524 mm [2 in. to 60 in.]. The Bandit’s base is 508 mm [20 in.] long.

Make sure there is enough room on the pipe for installa on. To ensure unimpeded movement of the interface lever, it is recommended the Bandit be mounted on a horizontal pipe.

When the portable Bandit is reposi oned, pressing the Suspend bu on a second me readies the portable Bandit to resume passage detec on. The Ac ve Func on Indicator F1–F2 cycle will cease.

NOTE: To avoid inadvertent triggering of a false passage, the portable Bandit should be put into Suspend Mode before reviewing previous

passages (see pg. 23). Exit Suspend Mode when you are fi nished reviewing previous passages.

nimpeded movement of e

be

nimpeded movement of e lever, it is recommended e mounted on pipe.


Page 28 of 44

INSTALLATION

1: Prep Banding

Prepare the band and buckle. Slide the buckle over the band and crimp in place.

2: A ach Base

Set the base on the pipeline. Loop the free end of the band through the slots at one end of the base.

Con nue looping the free end around the pipe un l it meets the buckle at the other end of the band.

Slide the free end of the band through the buckle.

*CDI Part # 81–04–0008–00

NOTE: The banding material and band tension

tool* are stocked by CDI.

NOTE: The standard CD52 antenna base (shown here)

is of cast aluminum and must be handled with care. Do not over-torque bands.

If needed, use electrical insulators (see pg. 32) to prevent interference with cathodic rec fi ers.


Page 29 of 44

INSTALLATION

3: A ach Tensioning Tool

Thread free end through both jaws of tension tool.

Tighten the tension on the band using the tension tool.

4: Cut Excess

Raise the tension tool to bend the band back over the buckle.

Pull the cutoff lever and cut off the excess banding material.

5: Secure Buckle

Secure the buckle. Bend the end of the band down by lightly tapping with a hammer. Using a hammer, bend the two locking tabs over the end of the band.

e

NOTE: Do not over-torque bands on cast aluminum antenna base.


Page 30 of 44

INSTALLATION

If you have any diffi cul es or ques ons assembling and installing your Bandit system, please feel free to contact CDI:

Telephone (worldwide): +1 (918) 258–6068

Email: [email protected]

Once installa on is complete, the face of the Bandit can be rotated as much as 180° in either direc on to obtain the desired orienta on for op mum viewing.

To do this, loosen the union joint and adjust the Bandit face to the desired posi on. Re- ghten union joint.

NOTE: Loosen union joint only enough to rotate Bandit. Do not disassemble union.


Page 31 of 44

INSTALLATION

Armored Flex Cable Units

Bandit units confi gured with armored fl ex cable are shipped mounted on a plywood sheet with webbing straps. Special unpacking procedures should be followed:

Required tools/materials:

• Screw gun or Phillips screwdriver

• Banding kit (supplied) • Ba eries (supplied)

1. Li mounted assembly with webbing handles only.

2. Remove antenna base unit strap using Phillips screw driver.

3. Uncoil cable. This requires two (2) personnel. Person #1 will hold antenna base (while suppor ng cable) and walk in an ever-widening circle. While walking, Person #1 will con nually untwist the antenna base to prevent cable from kinking.

Person #2 will be responsible for uncoiling cable at the plas c spool.

4. Startup procedure is iden cal to that of standard units.

NOTE: Prepare an unobstructed 6 m x 6 m [20 x 20 ] area before unpacking.

NOTE: Maintain a 152 mm [6 in.] minimum bend radius to avoid kinking or breaking the aluminum cable armor.

d l h l


Page 32 of 44

OPTIONAL EQUIPMENT

OPTIONAL EQUIPMENT

Remote Indicator System (RIS)

The Remote Indicator System (RIS) consists of four high-luminosity LEDs that, when pig passage occurs, can be seen over distances as great as 100 meters [328 ].

The RIS may be added to any Bandit System.

Cathodic Protec on Base Moun ng

Cathodic protec on insula on ma ng is available to protect pipeline coa ng.

Heater

A 24 VDC internal heater is available and recommended for opera on in temperatures below –30°C [–22°F].

Heat Risers

Heat riser insulators for the CD52 Bandit allow the system to be used on geothermal pipeline, or other environments where pipeline surface temperatures exceed of 80°C [176°F].

Sunshade

The stainless steel sunshade can help protect the Bandit from intense sunlight by reducing overall temperature inside, thus prolonging the life of the electronic components. The sunshade’s 316 stainless steel construc on guarantees long life in a harsh pipeline environment and is available for all Bandit variants.


Page 33 of 44

OPTIONAL EQUIPMENT

LineStat

TRAXALL LineStat is a global, value-added satellite-based event no fi ca on service provided by CDI and targeted primarily to the oil and gas pipeline industry. LineStat provides no fi ca on to email addresses and SMS text messaging telephone numbers of remote events from both fi xed posi on and portable equipment.

Some of the details included in event no fi ca on messages are date, me, GPS posi on, ba ery status, and vibra on.

This informa on is transmi ed via satellite without use of cellular networks and without

need of a wired infrastructure.

TRAXALL 720/770 Mul -source Pig Loca on and Tracking System

The TRAXALL 720 and 770 track CDI X-Series electromagne c transmi ers, pigging industry-standard 22-Hz “Legacy” transmi ers, and magne c-fl ux leakage (MFL) pigs.

This advanced tracking and loca ng tool also includes built-in GPS and Bluetooth communica on.

The TRAXALL is ideal for passage detec on, pinpoin ng, and launch/receive verifi ca on.

Sonopo

histh

edast

S

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Page 34 of 44

WARRANTY

WARRANTY

All equipment sold by Control Devices, Incorporated (CDI) is warranted for a period of one (1) year from the date of shipment to Purchaser, providing the instrument or equipment has not been modifi ed, abused or used for purposes other than that for which it was designed.

Ba eries, probes, leads, magnets and other consumables subject to wear are not covered by this warranty. CDI will repair or replace faulty equipment during the warranty period when the cause is a defect arising from faulty design, materials or workmanship.

Making a Warranty Claim

Equipment being considered for warranty repair, or a representa ve sample thereof, must be returned to CDI at the Purchaser’s expense. The equipment must be accompanied by the Purchaser’s wri en order* describing the defect(s) and authorizing CDI to invoice the Purchaser for any charges not covered by the warranty.

Upon receipt of the equipment and Purchase Order, CDI will examine the equipment and make a determina on of the nature and cause of the defect. If the defect is not covered by the warranty, CDI will quote to Purchaser the cost for replacement or repair equipment, and will not proceed un l Purchaser delivers a wri en acceptance of the quota on.

During the one year warranty, CDI will bear the cost to return units repaired under the warranty back to the Purchaser’s domes c premises. CDI will return units to foreign countries at Purchaser’s expense.

* Contact CDI at 1–800–580–4234, ext 143 for CDI RMA Form FM–03–0089


Page 35 of 44

SERVICE & MAINTENANCE

Care and Maintenance

Equipment designed by CDI is protected against the environment in which it is intended to operate. Much of the equipment is designed for prolonged use in the fi eld without any special maintenance other than rou ne ba ery replacements. It is the Purchaser’s responsibility to insure that proper precau ons are taken during installa on and opera on so that weather seals are in place, rou ne maintenance occurs, etc. Failure to perform these opera ons nullifi es this warranty.

CDI equipment should only be operated by qualifi ed personnel who are familiar with any and all manuals and procedures for said equipment’s opera on.

Opera ng equipment while in a damaged condi on nullifi es this warranty.

Service and Repairs

Cost for repairs not covered by the warranty or carried out a er the warranty period has expired will be charged at the current hourly or set service rate, plus the cost of materials, upon approval by Purchaser.

Equipment for repair must be sent at the Purchaser’s expense and be accompanied by the Purchaser’s wri en order describing the defect and authorizing CDI to invoice the Purchaser for labor, materials and return delivery cost.

No service or repair will be undertaken un l an approved wri en order is received from the Purchaser.

Opera ng equipment while in a damaged condi on nullifi es this warranty.


Page 36 of 44

GEN ARRANGEMENT DWGS

GENERAL ARRANGEMENT DRAWINGS


Page 37 of 44



Page 38 of 44


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Page 39 of 44



Page 40 of 44



Page 41 of 44

SYSTEM SPECIFICATIONS


Detec on Type: Non-Intrusive, Magne cDevices Detected: CD42 Transmi ers or CD52 Permanent MagnetsDetec on Direc on: Bi-Direc onal

Passage Visual Indicator: LCD blinks one hour a er passage LCD holds steady for next 11 hours Auto-Resets at 12 hours

Passage Electrical Indicator: Isolated Dry Contact Closure

Detec on Speed: 0.01 meter/sec to 20 meter/sec

Ba ery Life: One full year minimum on two standard 1.5 VDC D-Cell alkaline ba eries

External Power: 24 VDC (21.6 to 26.4 VDC Allowable Range) Enclosure: AluminumWindow: Tempered Glass System Cer fi ca on:

CSA–UL Standard C22.2 No.30 rated for Class 1 Division 1 explosion-proof environments groups C and D

Tamb –50°C to +80°C (24 VDC Power) Tamb –50°C to +45°C (Ba ery)

Line Sizes: 152 mm to 1524 mm [6 in. to 60 in.]Pipe Wall Thickness: Up to 38.1 mm [1.5 in.]

Pipe Moun ng Assembly: Aluminum (316 Stainless Steel op onal)Banding and Buckles: 201 Stainless Steel (316 Stainless Steel op onal)

NOTE: Where pipe wall thickness exceeds 25.4 mm [1 in.], a custom

magnet design may be required. Please consult CDI for an evalua on of deployment op ons.


Page 42 of 44


Contact Closure: Electrically Isolated Double Pole – Double Throw Available in normally-open or normally closed confi gura ons w/customer-specifi ed relay dwell me

Contact Closure Current Capacity: 2 Amps at 30 Volts DC Opera onal Temperature Ranges:

LineStat Satellite Equipped System: –30°C to 80°C [–22°F to 176°F]

Heat Risers Required with Product Heat > 80°C [176°F] Total Passage Count: 10 (First In, First Out)

Stored Passage Informa on: Time and Date of passages. Informa on is stored through loss of power. System Design Life: 20 yearsStorage Life: 20 years


Page 43 of 44

MAGNET MOUNTING

PIG MAGNET MOUNTING

CD42-Tx and TRAXALL X-series electromagne c transmi ers and CD52-MX series magnets and can be mounted onto foam, uni-cast, or metal pigs.

Virtually any pig may be equipped to be detected by the CD52 Bandit system.

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ABOUT CDI

CDI is a family-owned and operated business located in Broken Arrow, Oklahoma, just 12 miles from downtown Tulsa. Incorporated in 1982, CDI has proudly been manufacturing products in the United States for more than 32 years. CDI currently employs 45 people in the areas of electronics and mechanical design, so ware and fi rmware programming, electronics manufacture, machining, and more.

All CDI products are designed and built completely in-house u lizing an on-premises machine shop boas ng six fully-automated CNC machines as well as full- me electronics assembly personnel.


Page 45 of 44

APPENDIX

SPECIAL SUPPLEMENT: REMOVE AND REPLACE CD52 BANDIT ELECTRONIC COMPONENTS

CD52 Bandit Electronic Components consist of several separate interconnected modules:

• Display • Ba ery Holder • Thermostat • User Board • Heater Board (if installed) • “Pig Module”

These modules are held in place by a series of short, medium, and long standoff s.

Required tools/materials:

• Phillips screwdriver, medium • Phillips screwdriver, small • 5/16-in nut driver or socket wrench • Diagonal cu er • Zip es

For clarity, a cutaway model is shown on the following pages.


Page 46 of 44

APPENDIX

1: Remove Ba eries

2: Cut Display Unit Cable Zip Tie

REMOVAL: DISPLAY UNIT


Page 47 of 44

APPENDIX

3: Disconnect Display Cable

4: Unscrew Display Screws (2)


Page 48 of 44

APPENDIX

5: Disconnect Display Ribbon Cable


Page 49 of 44

APPENDIX

6: Remove Ba ery Holder Screws

7: Disconnect Ba ery Holder Power Cable

REMOVAL: BATTERY UNIT


Page 50 of 44

APPENDIX

8: Li Off & Disconnect Thermostat

REMOVAL: THERMOSTAT


Page 51 of 44

APPENDIX

9: Remove Small Standoff s From User Board

10: Disconnect 24V Cable From User Board

REMOVAL: USER BOARD


Page 52 of 44

APPENDIX

12: Remove and Invert User Board

13: Unfasten User Board Connector and Detach Ribbon Cable


Page 53 of 44

APPENDIX

14: Remove Medium Standoff s from Heater Board

15: Li Off Heater Board

REMOVAL: HEATER BOARD


Page 54 of 44

APPENDIX

16: Remove Ground Wire from “Pig Module”

17: Disconnect Antenna Cable

REMOVAL: “PIG MODULE”


Page 55 of 44

APPENDIX

18: Remove Long Standoff s From Pig Module

18: Remove Pig Module

You are now ready to replace components.


Page 56 of 44

APPENDIX

As men oned earlier, a cutaway model is shown hear for clarity. Note permanent standoff s at back of unit shell.

1: CAREFULLY insert Pig Module. You will have to angle the module as shown.

REPLACEMENT: “PIG MODULE”


Page 57 of 44

APPENDIX

3: Seat Pig Module onto standoff s. Ensure ground wire is clear of standoff s and module.

4: Reinstall Ground Wire


Page 58 of 44

APPENDIX

5. Reinstall Long Standoff s.

6: Rea ach Antenna Cable.

REPLACEMENT: “PIG MODULE” (cont.)


Page 59 of 44

APPENDIX

7. Reinstall Heater Board.

8: Reinstall Medium Standoff s.

REPLACEMENT: HEATER BOARD


Page 60 of 44

APPENDIX

9. Rea ach User Board Ribbon Cable Connector.

10: Reposi on User Board and Replace Medium Standoff s.

REPLACEMENT: USER BOARD


Page 61 of 44

APPENDIX

11. Rea ach 24V Cable Connectors

Note 4-pin and 3-pin connectors.


Page 62 of 44

APPENDIX

12. Rea ach Thermostat Board Ribbon Cable.

13: Reposi on Thermostat Board. Ensure Holes are lined up properly.

REPLACEMENT: THERMOSTAT BOARD


Page 63 of 44

APPENDIX

14. Reconnect Ba ery Holder Power Cable.

15. Line Up Ba er Holder with Thermostat Board. (Avoid binding Thermostat Board Ribbon Cable.)

REPLACEMENT: BATTERY HOLDER


Page 64 of 44

APPENDIX

16. Rea ach Ba ery Holder.

REPLACEMENT: BATTERY HOLDER (cont.)


Page 65 of 44

APPENDIX

17. Rea ach Display Board Ribbon Cable.

18. Rea ach Display Board.

REPLACEMENT: DISPLAY UNIT


Page 66 of 44

APPENDIX

17. Rea ach Display Board Ribbon Cable.

18. Rea ach Display Board.

REPLACEMENT: DISPLAY UNIT (cont.)


Page 67 of 44

APPENDIX

19. Rea ach Display Board Zip Tie.

18. Replace Ba eries.

Documents

CD52 BANDIT USER MANUAL CSA-UL 15 MAR 2016 BANDIT USER MANUAL... · CD52 Bandit (CSA-UL Cer ﬁ ca on) User Guide Page 3 of 44 WARNING Any opera on involving work on pipelines containing