3 Installation 6
∙ Sensor location 6
∙ Do's and Dont's 7
∙ Main Line 9
∙ Removal 12
∙ Analyzer Loop 13
∙ Wiring 14
∙ Connecting the OFD 15
4 Field Calibration 16
5 Maintenance 18
Appendix A Modbus Register 22
CAUTION:
When installing the OFD™ sensor in a pipeline containing petroleum products,
petrochemicals, waste waters with the presence of pressure & temperature, and high-pressure
steam refer to the Pipeline Operators’ “Health, Safety and Environmental Policy Procedures” to
ensure safe installation.
KAM CONTROLS, INC. reserves the right to make changes to this document without notice.
OFDMANUAL 0816
1
Page 3
INTRODUCTION
AVAILABLE MODELS and MOUNTING OPTIONS
FIG. 1-1FIG. 1-2FIG. 1-3
Fullopening
Ball
Valve
Rectractable OFD™
on a main pipe, with
2", 3", or 4" flanged
seal housing
Fullopening
Ball
Valve
Rectractable OFD™
on a main pipe, with
2" MNPT seal housing
OFD™ FT Flow Through
on a densitometer loop
with ¾" or 1" MNPT
OFDMANUAL 0816
2
Page 4
SPECIFICATIONS
Media: Refined products
Material: Wetted parts–316 stainless steel
Power: 12–24 VDC 15 Watts max (Max current is 1275 mA @ 12V and 637 mA @ 24V)
2", 3", or 4" Flanged Seal Housing Insertable/Retractable
EX enclosure: 3" x 6" x 3" (76 mm x 152 mm x 76 mm)
Shaft length: 12" to 60" – Off-the-shelf lengths are 24", 30", 36", 48", and 60"
(610 mm to 1524 mm)
(Off-the-shelf 610 mm, 762 mm, 914.4 mm, 1219 mm, 1524 mm)
Pipe size: 3/4" to 48" (20 mm to 1200 mm)
Weight: from 10 lbs. (4.5 kg)
OFDMANUAL 0816
3
Page 5
L= 24" 30" 36" or 48" other sizes can be
SPECIFICATIONS CONTINUED
DIMENSIONAL DRAWINGS
FIG. 2-1 OFD™ Sensor with Flanged Seal Housing
SL
C (Shaft Diameter)
B
A
TABLE 2-2 Flange Size and Class (SL)
150
"
2
3
4
INCHES
8.40
8.60
8.60
MM
213
218
218
Seal Housing
Shaft Length ± .5"
300
INCHES
8.50
8.75
8.90
600
MM
216
INCHES
8.90
MM
226
222
226
9.15
9.40
232
240
E
¾" FNPT
INCHES
9.40
9.40
9.65
D
900
MM
240
240
245
TABLE 2-3 DIMENSIONS
INCHES
A
B
C
D
E
OFDMANUAL 0816
1.443
1.25
1
4.53
7
MM
37
32
25
115
178
Shaft Lengths are available in .5" (12.7
mm) increments.
Standard sizes are 24", 30", 36", 48",
and 60". (610 mm, 762 mm, 914.4 mm,
1219 mm, 1524 mm)
4
Page 6
SPECIFICATIONS CONTINUED
FIG. 2-4 FLOW THROUGH OFD™ for ANALYZER LOOP
E
D
C
B
F
A
¾" or 1"
MNPT
H
TABLE 2-5 ¾" MNPT DIMENSIONS
A
B
C
D
E
F
INCHES
.3
.5
1. 4
2.25
6.75
7
MM
8
13
36
57
171
178
¾" FNPT
TABLE 2-6 1" MNPT DIMENSIONS
A
B
C
D
E
F
INCHES
.3
.5
1.45
2.4
6.75
7
MM
8
13
37
61
171
178
G
G
H
OFDMANUAL 0816
4.53
1. 2
115
30
G
H
4.53
1. 3
115
33
5
Page 7
INSTALLATION
TERMINAL FENCE
LOCATION
For optimal batch detection, KAM CONTROLS recommends that you install the in-station OFD™ sensor at the
first accessible pipeline location inside the terminal fence-line — upstream of the interface cut valve(s). This allows the operator ample time to open/close the cut valves prior to the arrival of the product interface.
KAM CONTROLS also strongly recommends that you utilize a preview (or out-station) OFD™ sensor. This lets the
operator decide how to optimize each batch cut prior to actually making the batch cut at the in-station and gives
the operator more confidence in their decisions as well as the time to identify and resolve any issues that may
arise during a critical interface.
FIG. 3-1 RECOMMENDED OFD™ LOCATIONS
TO TANK
OUT-STATION/PREVIEW
INCOMING
OFD
OFD
TYPICALLY
1 - 2 MILES
(1.6–3.2km)
IN-STATION/CUT
OFD
CUT VALVES
TO TANK
TO TANK
TERMINAL FENCE LINE
PRIOR TO INSTALLATION
Remove all the protective packaging materials including the red cap placed at the tip of the sensor probe. Ensure that the OFD™ sensor was not damaged during transit.
CAUTION: Do not stand the OFD™ sensor on the probe end or allow the probe to hit the ground or any hard
surface under any circumstances. This will damage the lens, and the OFD™ sensor will not work properly.
OFDMANUAL 0816
6
Page 8
INSTALLATION CONTINUED
INSTALLATION DO’S AND DON’TS
DO NOT install the
fast loop OFD™
sensor in a straight
portion of pipe.
It needs to be
mounted off the
bend opposite the
P
pump.
P
FLOW
FLOW
FLOW
DO NOT install the
OFD™
sensor with the
lens facing directly
into the flow. If
the product has
particulate
P
P
FLOW
FLOW
matter in the fluid,
like sand, this will
sandblast the lens
and could cause
premature failure.
FLOW
FLOW
P
FLOW
I
I
P
FLOW
FLOW
OFDMANUAL 0816
DO NOT attempt to
screw the OFD™
sensor either in
or out by hand.
Always use a
1 1/4" or 1 3/8"
wrench on the
wrench flat below
the electronics
enclosure.
7
P
FLOW
FLOW
Page 9
P
INSTALLATION CONTINUED
INSTALLATION DO’S AND DON’TS
DO NOT use teflon
tape on the OFD™
sensor threads. DO
use liquid thread
sealant.
DO install the
OFD™ sensor with
a minimum of 8"
or 200mm between the lens and
the nearest flat
surface.
Minimum 8"
(20.3 cm)
P
FLOW
FLOW
DO install the
OFD™ sensor with
a sun shade if the
electronics are
directly exposed to
sunlight.
OFDMANUAL 0816
8
Page 10
INSTALLATION CONTINUED
PRIOR TO INSTALLATION
Remove all the protective packaging materials, and ensure that the OFD™ sensor was not damaged during transit.
MAIN LINE INSTALLATION
The KAM® OFD™ sensor should be installed
according to FIG. 3-2. KAM CONTROLS
recommends installing the OFD™ sensor at a 2 or
10 o’clock position to ensure the tip of the probe
remains in the fluid. A full opening ball valve is
used to isolate the OFD™ sensor from the pipeline
during installation or removal. The seal housing of
the OFD™ sensor allows the optical probe to be
inserted and removed from the pipe under pressure
and flow conditions. It is the user’s responsibility to
ensure that the OFD™ sensor is placed at the most
representative point within the flow profile. The
OFD™ sensor should be inserted so that the tip of
the probe is located 1/4" above the inner wall of the
pipeline. This ensures that the probe is not
damaged when pigging the pipeline.
NOTE: If line pressure exceeds 100 psi, use a KAM®
IT Insertion Tool when installing/removing
the KAM® OFD™ sensor.
Prior to mounting the OFD™ sensor on the
Full-opening Ball Valve, you must determine
the insertion length required.
FIG. 3-2
Locking Collar
Seal Housing
Full-opening
Ball Valve
Socket Cap
Screw
FIG. 3-3
Lay the OFD™ sensor on the ground or a table.
1.
2.
Loosen Socket Cap Screws on the locking
collar. This will allow the OFD™ shaft to slide
through the seal housing.
3.
Push the OFD™ shaft though the seal housing
until the OFD™ probe sits flush with the end of
the seal housing or seal housing flange. FIG.
3-3 and 3-4. (Remove red protection cap on the
tip of the probe if it has not been removed.)
4.
Place a mark with a sharpie or a permanent
marker on the shaft at the edge of the locking
collar. (Do not use anything sharp to mark the
shaft as this will create grooves that will
damage the O-rings in the seal housing.)
Mark here
FIG. 3-4
Mark here
OFDMANUAL 0816
9
Page 11
INSTALLATION CONTINUED
5.
Pull shaft back until the probe is all the way in the seal housing and tighten the socket cap
screws on the locking collar. This will prevent the OFD™ shaft from sliding and the probe from getting damaged
during mounting.
Measure the distance (D1) from the outside diameter of main pipe to the end of the connection where the OFD™
6.
sensor is going to be installed. FIG. 3-5.
FIG. 3-5
D1
D1
7.
Calculate the insertion distance for Flanged Seal Housing (If you have a MNPT Seal Housing, proceed to
step 9):
Total Insertion Distance (TID) = D1 + Pipe Wall Thickness + Seal Thickness -1/4"
Example for D1= 19", Pipe WT=3/8", and Seal Thickness is 1/8"
TID=19 + 3/8 + 1/8 – 1/4 or TID=19 + .375 + .125 – .25
TID= 19 1/4" or 19.25"
8.
Use the calculated TID and mark a second line on the shaft, measuring from first mark. FIG. 3-6.
FIG. 3-6
TID
First Mark
Second Mark
9.
Bolt or screw the OFD™ sensor to the valve or designated installation location.
(KAM CONTROLS recommends using thread sealant and not Teflon tape for the threaded OFD™). Skip to Step 12
(OFD with Flanged Seal Housing only).
OFDMANUAL 0816
10
Page 12
INSTALLATION CONTINUED
Calculate the Insertion distance for 2" MNPT Seal Housing:
10.
TID cannot be calculated until the Seal Housing is screwed into place. If you have not already done so, please
screw your OFD™ sensor into place now.
You must then measure the Threaded Depth (TD) into the Valve or connection in order to calculate TID. You
can do this by measuring the distance from the edge of the Valve or female connection to the top of the Seal
Housing body and subtracting that distance from 5.25". FIG. 3-7.
FIG. 3-7
For example:
Measuring points
If the measured distance from the top of the valve to the top of the seal housing
body is 4.75", you would calculate the threaded depth (TD) by subtracting 4.65" from 5.25".
(5.25 – 4.65=0.6) In this case the threaded depth TD would be .6".
You are now ready to calculate TID.
TID= (D1) + (Pipe Wall Thickness) – (TD) – (.25")
Example for D1=19", Pipe WT=3/8", and TD=.6"
TID=(19)+(.375)-(.6)-(.25)
TID=18.525"
Use the calculated TID and mark a second line on the shaft, measuring from first mark. FIG. 3-8.
11.
FIG. 3-8
TID
First mark
Second mark
OFDMANUAL 0816
11
Page 13
INSTALLATION CONTINUED
12.
If you have an OFD™ with a Flanged Seal Housing, you may now attach it to the valve on the pipeline.
13.
Slowly open Full-opening Ball Valve and check for leaks.
14.
Loosen Socket Head Screw on the Locking Collar.
Push the OFD™ in until the Second Mark is at the top edge of the Locking Collar. FIG. 3-9.
15.
FIG. 3-9
Second Mark
10.
Re-tighten the Socket Cap Screws.
11.
Tighten the Hex Nuts on the top of the Locking Collar one half turn. These nuts should
never be over tightened. Their major function is to apply light pressure on the chevron packing to
ensure a seal between the seal housing body and the insertion shaft.
REMOVING THE OFD™ SENSOR
To remove the OFD™ sensor, first disconnect all
1.
electrical connections to the OFD™ enclosure.
Make sure that the line pressure is below 100 psi.
2.
Then, slowly and with caution loosen the Socket
Cap Screws on the Lock Down Collar.
NOTE: Once the Socket Cap Screws have been
loosened, the OFD™ shaft may push out from the
line. If pressure in the line is above 100 psi, it may
do so with enough force to cause bodily injury or
damage to the instrument.
3.
Slide the OFD™ sensor upward until it stops and
the probe rests inside the seal housing. FIG. 3-10.
4.
Next, close the Full-opening Ball Valve tightly. The
OFD™ sensor may now be unbolted from the system.
FIG. 3-10
Socket Cap Screws
OFDMANUAL 0816
12
Page 14
INSTALLATION CONTINUED
ANALYZER LOOP INSTALLATION
KAM CONTROLS recommends this installation for 3/4" & 1" MNPT OFD™ sensors.
We recommend using thread sealant and not teflon tape for the OFD™ sensor threads.
CAUTION: DO NOT USE THE ENCLOSURE TO TIGHTEN OR LOOSEN THE OFD. THIS CAN CAUSE THE PROBE TO
COME UNDONE AND THE FIBER CABLE TO BREAK. Please refer to “Do’s and Don’ts” on pages 8-9.
KAM 3/4" and 1" MNPT OFD™ sensors should be
installed according to FIG. 3-10. The OFD™ sensor should be installed in an analyzer loop in such a
fashion that the flow sweeps across the probe lens
rather than rushing directly at the probe. The reason
for this is to:
1) obtain a credible reading of the product
pipeline interface
2) keep the lens of the probe clean and abrasion
free. If the OFD™ is installed with the product
rushing directly at the probe, particles in the pipeline
can scratch the lens causing abrasions and resulting
in a non-credible reading.
You do not need to measure for insertion distance
on the fast loop models.
FIG. 3-11
Flow
P
Pump
Flow
OFDMANUAL 0816
13
Page 15
INSTALLATION CONTINUED
WIRING
FIG. 3-12
12 or 24 VDC / 1 amp
power supply
KAM serial cable
(diagnostics only)
5
V
T
D
P
T
4
C
P
3
A
RS232 RXD
CHS GND
RS232 TXD
GND
24/12 VDC (+)
24/12 VDC (-)
5
V
D
T
C
P
-
1
D
T
P
7
3939 ANN ARBOR DRIVE
HOUSTON TX - 77063
Tel. +1-713-784-0000
Fax: + 1-713-784-0001
www.Kam.com
KAM OID
MADE IN USA
G
N
T
D
P
2
485 RX
CHS GND
485 TX
CHS GND
4-20 mA (+)
4-20 mA (-)
O
G
F
A
F
I
N
T
S
P
E
5
T
-
3
5
.
V
3
D
V
D
C
C
To grounding rod (preferred)
or enclosure
500 Ohm
max load
CAUTION: OFD provides the power
for the 4-20 mA load.
Do NOT apply external voltage, as
this will damage the 4-20 mA output.
POWER
V (+)
GND
COMMUNICATION INTERFACE
RS232 (diagnostics)
RS485 (Modbus RTU)
OUTPUTS
4-20 mA (–) Current output, source powered
4-20 mA (+)
CAUTION: When electronics enclosure is open, be
extremely careful to avoid any contact with interior fiber
optic connections. Failure to do so could result in the
OFD malfunctioning.
OFDMANUAL 0816
14
Page 16
INSTALLATION CONTINUED
CONNECTING THE OFD
1.
Proper Grounding of the OFD™ sensor.
Grounding the OFD™ sensor through the 4-20 mA signal out and power lines is not adequate to protect the
OFD™ sensor against power surges.
To ground the OFD™ sensor, connect the chassis ground on the OFD™ board (labeled CHS on the OFD™
Terminal Block. FIG. 3-13) to the green grounding screw on the OFD™ explosion-proof box using 16 AWG braided
wire. Ensure that the box is connected to Earth ground either through the pipeline or appropriate low-impedance
buried grounding structure.
NOTE: CHS is isolated from GND. Grounding CHS to pipeline through the grounding screw will not short OFD™
GND to the pipeline.
To connect the power for the OFD™ sensor, first check both wires from the source for polarity and
2.
voltage, then label appropriately.*
3.
Connect positive wire to 24/12 VDC (+). FIG. 3-13.
4.
Connect negative wire to 24/12 VDC (-).** FIG. 3-13.
5.
Check voltage and polarity at terminal block.
FIG. 3-13
P
5
T
F
F
O
A
G
I
D
N
G
P
T
P
T
D
5
V
C
P
T
D
5
V
C
T
P
4
C
D
3
3
.
V
5
-
V
C
D
S
E
T
N
2
1
T
P
7
HOUSTON TX - 77063
D
-
3
A
-
3939 ANN ARBOR DRIVE
Chassis Ground
4-20 mA (+)
485 TX
485 RX
CHS GND
MADE IN USA
KAM OID
www.Kam.com
Tel. +1-713-784-0000
Fax: + 1-713-784-0001
CHS GND
RS232 TXD
RS232 RXD
4-20 mA (-)
CHS GND
GND
24/12 VDC (-)
24/12 VDC (+)
Power Supply
EXTERNAL FUSES: Power Amp slow fuse, Current loop 750 mA
MAXIMUM CURRENT LOOP RESISTANCE: 500 Ohm
*Recommended Wire: Shielded twisted pair wire is recommended for both power and signal.
**WARNING: Connecting a power source to the 4-20 mA ports on the TB will damage the 4-20 mA ouput and result
in failure of the unit.
OFDMANUAL 0816
15
Page 17
FIELD CALIBRATION
The OFD is factory calibrated such that 4 ppm of fluorescent dye is equal to 20 mA and should not require
calibration. However, if operators change dye levels, some fine-tuning may be necessary.
INCREASE SENSITIVITY WHEN dye levels are below 4 ppm or when readings from dyed product are
typically falling in the lower or middle portion of the KAM® OFD™ output range.
DECREASE SENSITIVITY WHEN dyed products levels are above 4 ppm or when readings exceed the
maximum reading of the pre-calibrated settings. Products that exceed the pre-set calibration readings will
produce an off-scale reading exceeding 20 mA. Decreasing sensitivity lowers the output
range of the KAM® OFD™ sensor to allow all readings to fall within the 4-20 mA output ranges.
Caution: When multiple KAM® OFD™ sensors are being used on the same system, each sensor should be
calibrated equally wherein fluids with 4 ppm of fluorescent dye are calibrated to 20 mA on the OFD.
The calibration procedure consists of increasing the gain or reducing the gain as needed to increase
or reduce sensitivity.
LED light output settings are pre-set at the factory and should not be adjusted.
REQUIRED TOOLS: VOLT METER, SMALL FLAT-HEAD SCREWDRIVER
CHANGING THE HIGH END OF OUTPUT RANGE IN LINE
1.
Determine when fluorescent dyed product will be at sensor,.
2.
Connect a volt meter across 4-20 mA terminals. With fluorescent dyed product flowing, increase the gain by
turning GAIN (FIG. 4-1) counterclockwise or decrease by turning clockwise. As you are turning, look at your
volt meter and stop when it reads 20 mA or 100% of scale.
CHANGING THE HIGH END OF OUTPUT RANGE OFF LINE
1.
Place the sensor tip of the OFD in a sample container with a dyed fuel sample containing the maximum
amount of dye in which the OFD will operate (usually 4 ppm). The sample should be in a container that is at
least 8” deep, and the tip of the sensor should be positioned at least 6” away from the bottom. The container
should should be sealed from any external light.
2.
Turn the OFD power on and wait for 5 minutes.
Connect a volt meter across 4-20 mA terminals. Increase the gain by turning GAIN (FIG. 4-1) counterclock-
3.
wise or decrease by turning clockwise. As you are turning, look at your volt meter and stop when it reads 20
mA or 100% of scale.
The low end of the range is set for non-dyed products or 0 ppm. Readings may vary somewhat but should not
exceed 5 mA.
FOR ALL OTHER TYPES OF ADJUSTMENTS CALL KAM CONTROLS, INC. +1 713 784 0000.
OFDMANUAL 0816
16
Page 18
FIELD CALIBRATION CONTINUED
FIG. 4-1
P
5
Maximum Output
Range Adjustment
T
F
F
O
S
A
G
I
D
N
G
P
T
P
T
D
5
V
C
-
P
T
D
5
V
C
T
P
4
C
D
3
3
.
V
5
-
V
C
D
E
T
N
2
1
3
-
T
P
7
MADE IN USA
KAM OID
www.Kam.com
HOUSTON TX - 77063
Tel. +1-713-784-0000
Fax: + 1-713-784-0001
D
3939 ANN ARBOR DRIVE
A
4-20 mA (+)
485 TX
485 RX
CHS GND
CHS GND
RS232 TXD
RS232 RXD
4-20 mA (-)
CHS GND
GND
24/12 VDC (-)
24/12 VDC (+)
OFDMANUAL 0816
17
Page 19
MAINTENANCE
CLEANING AND INSPECTION
Under normal operation, the KAM OFD should not require cleaning, unless pipeline usage is limited to a small
number of products. Gasoline products or jet fuel in the pipeline will clean the OFD without removal.
To remove any oil residues for visual inspection use a clean cloth with oil solvent or part washer.
Preferred solvents include, any petroleum solvent such as mineral spirits, isopropyl alcholhol, gasoline, or diesel.
Do not use other chemicals.
If you have a question regarding cleaning solvents, please contact KAM CONTROLS directly at
+1 713 784-0000, or email: AskAnEngineer@Kam.com
DIAGNOSTICS VIA RS232
Connecting to the RS232 Serial Port using RealTerm
1.
Install RealTerm if not installed on your PC.
• RealTerm Software can be Downloaded at http://sourceforge.net/projects/realterm/les/Realterm/2.0.0.70/
• Click on Realterm_2.0.0.70._setup.exe to install.
2.
Connect the RS232 cable to the OFD as shown in the wiring diagram. FIG. 3-12 on page 15.
3.
Connect the other end of the RS232 Cable to your computer serial port or to USB with the provided serial
converter.
4.
Open RealTerm. A window will open up as shown in Fig. 5-1.
5.
The program will open on the "Display" tab. Click on the up arrow of the "Cols" window until it reaches 120.
Do not try to type the number in the window as it will result in an error. If you do this, you must close the
program and start again.
FIG. 5-1
Display tab
OFDMANUAL 0816
Click until display
equals 120
18
Page 20
MAINTENANCE CONTINUED
Click on the "Port" Tab (See FIG. 5-2), and change the settings as follows:
6.
a. Baud = 115200
b. Parity = None
c. Data Bits = 8
d. Stop Bits = 1
e. Hardware Flow Control = None
f. Port = Select Port number assigned to your serial port or USB to serial converter
g. Click on the Change button to save these settings.
FIG. 5-2
Port settings
Port tab
Change to save
Select port number
OFDMANUAL 0816
19
Page 21
MAINTENANCE CONTINUED
Click on the "Send" tab.
7.
Check the first 4 boxes in the "EOL" section.
8.
Type "?version" in either of the command boxes and click the "Send ASCII" button. You will a see message on the
9.
window displaying the software version number, the version date and the schematic version of the board.
FIG. 5-3
EOL section
Command boxesSend tab
To view output data, type the command "=ostart,c,20" and click on Send ASCII. See FIG. 5-4 on page 22.10.
11. Type the command "=ostop,c" to stop the data. Always do this before disconnecting.
OFDMANUAL 0816
20
Page 22
MAINTENANCE CONTINUED
FIG. 5-4
Column 14 - CRC Cyclic Redundancy
check for information only
Column 13 – Electronics temperature
Column 12 – OFD output on a 4-20mA range
Column 11 – OFD output on a 0-100% range
Column 10 – Signal in counts after any compensations such
as compensation for temperature.
Column 9 – Value of the photodiode monitoring the LED when it
is ON. This value is shown in counts and should be between 500
& 800. If the LED is damaged and not turning on this value will be
the same as in column 8.
Column 8 – Value of the photodiode monitoring the LED when it is
OFF. This value is shown in counts and should be less than 50.
Column 7 – Reference Voltage that controls the High Voltage supply.
This value should be between .720 to .880 VDC
Column 6 – MPPC Photodiode Temperature, controlled by a thermoelectric cooler
inside the photodiode. The factory temperature is between 14C and 16C.
Column 5 – High Voltage supply going to the MPPC Photo diode. The range is
from 46.5 VDC to 58.0 VDC.
Column 4 – Signal value from the MPPC photodiode. This value is also in counts. It has range
from 6553 ± 500 to 58982 ( 0.5Vto 4.5V) depending on the product that the probe is seeing.
Column 3 – Offset value in counts. The factory offset should be around
6553 ±500. To convert the value to volts divide the value shown by 13107.