Weir Group Management Services STXMPM Operators Guide

The Weir Group PLC

Weir Mechatronics

1 Marden St Artarmon, NSW 2064, Australia Tel: +61 2 9934 5100

Weir Industrial Gateway

Setup guide

Document ID: 00-40-20-40_20

Revision: 0.5

November 15, 2017

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Name

Designation

Date

Signature

Submitted By

C.Strudwicke

Principle Control Systems Engineer

Accepted By

C.Strudwicke

Principle Control Systems Engineer

Approved By

B.Baker

Head of Mechatronics

Document Approval

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Revision

Date

Author

Details

0.1

9-3-2017

C.Strudwicke

First version

0.2

21-03-2017

C.Strudwicke

Addition of feedback relating to certification requirements

0.3

08-09-2017

W. Cooke

Addition of feedback relating to certification requirements

0.4

10-06-2017

W. Cooke

Addition of feedback relating to certification requirements

0.5

11-15-2017

W. Cooke

Document name change to match regulatory documents

Document History

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Table of Contents

DOCUMENT APPROVAL .................................................................................................................................. I

DOCUMENT HISTORY .................................................................................................................................... II

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

1.1 INTRODUCTION .......................................................................................................................................... 1

1.2 SCOPE ...................................................................................................................................................... 1

1.3 TARGET AUDIENCE ...................................................................................................................................... 1

1.4 SAFETY ..................................................................................................................................................... 1

1.4.1 Safety Terminology and Symbols ...................................................................................................... 1

1.4.2 User Safety ........................................................................................................................................ 1

1.4.3 Warnings ........................................................................................................................................... 2

1.4.4 Determination That Equipment Can be Used Safely in the Intended Area ........................................ 3

2 TRANSPORTATION AND STORAGE ......................................................................................................... 4

2.1 CONSIGNMENT RECEIPT AND UNPACKING ........................................................................................................ 4

2.2 TRANSPORTATION GUIDELINES ...................................................................................................................... 4

2.3 STORAGE .................................................................................................................................................. 4

3 SYSTEM COMPONENTS ......................................................................................................................... 4

4 SYSTEM ARCHITECTURE ......................................................................................................................... 6

5 PSM – POWER SUPPLY MODULE ............................................................................................................ 7

5.1 PARAMETERS RELEVANT TO INSTALLATION AND OPERATION ................................................................................ 7

5.2 INSTALLATION ............................................................................................................................................ 8

6 MPM – MAIN PROCESSING MODULE ..................................................................................................... 9

6.1 PARAMETERS RELEVANT TO INSTALLATION AND OPERATION ................................................................................ 9

6.2 IMAGES .................................................................................................................................................... 9

6.3 CONNECTOR KEYING TYPES ........................................................................................................................ 12

6.4 LED INDICATORS ...................................................................................................................................... 12

6.5 INSTALLATION .......................................................................................................................................... 13

Mounting plate & Hardware ............................................................................................................... 13

6.5.1 .............................................................................................................................................................. 13

6.5.2 MPM & PSM .................................................................................................................................... 14

6.5.3 Hazardous Location Requirements .................................................................................................. 16

6.5.4 Antenna ........................................................................................................................................... 17

7 RSP – REMOTE SIGNAL PROCESSOR ..................................................................................................... 22

7.1 PARAMETERS RELEVANT TO INSTALLATION AND OPERATION .................................................................. 22

7.2 IMAGES ................................................................................................................................................. 22

7.3 CONNECTOR KEYING TYPES ........................................................................................................................ 24

7.4 LED INDICATORS ...................................................................................................................................... 25

7.5 INSTALLATION .......................................................................................................................................... 26

7.5.1 Physical mounting ........................................................................................................................... 26

7.5.2 Hazardous Location Compliance ..................................................................................................... 26

7.5.3 Protective Earth Grounding for Non Hazardous Locations .............................................................. 27

7.5.4 Connection to MPM ........................................................................................................................ 27

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

8 JUNCTION BOXES AND CABLES ............................................................................................................ 30

8.1 LIST OF CABLES ......................................................................................................................................... 30

8.1.1 Connecting to RSP ........................................................................................................................... 30

8.1.2 Junction Box to sensor ..................................................................................................................... 30

8.2 LIST OF JUNCTION BOXES ........................................................................................................................... 31

8.3 INSTALLATION .......................................................................................................................................... 31

9 SENSORS ............................................................................................................................................. 32

9.1 LIST OF APPROVED SENSORS ....................................................................................................................... 32

9.2 HAZARDOUS LOCATION NON-INCENDIVE SENSORS .......................................................................................... 33

9.3 SENSOR INSTALL LOCATIONS ....................................................................................................................... 33

9.4 INSTALLATION .......................................................................................................................................... 34

9.4.1 Mounting point Preparation ........................................................................................................... 35

9.4.2 Adhesively bonded mounting puck .................................................................................................. 35

9.4.3 Drilled and tapped mount ............................................................................................................... 36

9.5 ACCELEROMETER ATTACHMENT ................................................................................................................... 38

9.5.1 Equipment and materials required .................................................................................................. 38

9.5.2 Installation ...................................................................................................................................... 38

9.5.3 VT-11 ............................................................................................................................................... 38

9.5.4 Removal ........................................................................................................................................... 39

9.6 TEMPERATURE RTD’S ............................................................................................................................... 39

9.6.1 Equipment and materials required .................................................................................................. 39

9.6.2 Hazards ........................................................................................................................................... 40

9.6.3 Installation ...................................................................................................................................... 40

9.6.4 Removal ........................................................................................................................................... 40

9.7 GLAND WATER FLOW METER AND PRESSURE TRANSDUCER .............................................................................. 40

9.7.1 Equipment and materials required .................................................................................................. 40

9.7.2 Possible Hazards .............................................................................................................................. 40

9.7.3 Installation ...................................................................................................................................... 40

9.8 SPEED – PROXIMITY SENSOR ....................................................................................................................... 41

9.8.1 Equipment and materials required .................................................................................................. 41

9.8.2 Hazards ........................................................................................................................................... 41

9.8.3 Installation ...................................................................................................................................... 42

10 CLEANING AND MAINTENANCE ............................................................................................................ 42

11 REGULATORY COMPLIANCE ................................................................................................................. 42

11.1 ELECTROMAGNETIC COMPATABILITY ............................................................................................................. 42

11.2 HAZARDOUS LOCATION COMPLIANCE ........................................................................................................... 43

11.3 SAFETY ................................................................................................................................................... 44

11.4 RADIO APPROVALS .................................................................................................................................... 44

11.4.1 FCC Requirements for Operation in the United States: ............................................................... 45

11.4.2 FCC RF Radiation Exposure: ........................................................................................................ 45

11.4.3 Industry Canada Requirements for Radio Operation in Canada: ................................................ 45

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Table of figures

Figure 1-1 Transient Protection Parameters, Line to Line and Line to Ground ........................ 3

Figure 4-1 System diagram ...................................................................................................... 6

Figure 5-1 Iso view of PSM ...................................................................................................... 7

Figure 5-2 PSM Connectors ..................................................................................................... 8

Figure 6-1 MPM perspective view (cables and protective shroud removed) ............................ 9

Figure 6-2 MPM with connector shroud installed ................................................................... 10

Figure 6-3 MPM connector view - protective caps installed ................................................... 10

Figure 6-4 MPM External dimensions .................................................................................... 11

Figure 6-5 Connector view ..................................................................................................... 11

Figure 6-6 Connector Keying, View from MPM Connector .................................................... 12

Figure 6-6 - MPM connector names and locations ................................................................. 12

Figure 6-7 MPM & PSM generic mounting plate .................................................................... 13

Figure 6-8 - MPM & PSU installed on mounting plate ............................................................ 15

Figure 6-9 SIM card receptacle in MPM ................................................................................. 15

Figure 6-10 24Vdc power connection from PSM to MPM ...................................................... 15

Figure 6-11 Mains AC power connection to PSM .................................................................. 16

Figure 6-12 Installation of Locking Clips ................................................................................ 16

Figure 6-13 Location of Protective Earth Grounding on MPM ................................................ 17

Figure 6-14 Antenna mount attached ..................................................................................... 18

Figure 6-15 Installation of Antenna(e) .................................................................................... 19

Figure 6-16 Antenna with and without cable attached ........................................................... 19

Figure 6-17 Antenna connector wrapped in protective tape ................................................... 20

Figure 6-18 Schematic of Wifi and Cellular antennae connections to MPM .......................... 20

Figure 7-2 RSP shown with connector shield installed .......................................................... 23

Figure 7-3 RSP Physical dimensions ..................................................................................... 24

Figure 7-4 RSP Connector layout and descriptions ............................................................... 24

Figure 7-5 Connector Keying, View from RSP Connector ..................................................... 25

Figure 7-5 RSP Connector port descriptions .......................................................................... 25

Figure 7-6 RSP Mounting Dimensions .................................................................................. 26

Figure 7-7 Location of Protective Earth Grounding on RSP ................................................... 27

Figure 7-8 MPM Comms + power connector on RSP ............................................................ 28

Figure 7-9 RSP comms + power connectors on MPM ........................................................... 28

Figure 7-10 PSM, MPM and RSP connected ......................................................................... 29

Figure 8-1 Installation of Locking Clips .................................................................................. 31

Figure 9-1 Sensor Install Locations ........................................................................................ 33

Figure 9-2 Slurry pump installation - mounting puck .............................................................. 34

Figure 9-3 Triblock mounting accessory ................................................................................ 34

Figure 9-4 Slurry pump - Mounting pump adhesively bonded to pump .................................. 36

Figure 9-5 Uni-axial accelerometer with connector and protective tape applied .................... 38

Figure 9-6 Tri-Block ................................................................................................................ 39

Figure 9-7 RTD ....................................................................................................................... 39

Figure 9-8 Gland water sensor installation ............................................................................. 41

Figure 9-9 Speed sensor mount example (new picture required) .......................................... 41

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

1 Introduction and Safety

1.1 Introduction

The purpose of this manual is to provide details on how to install the Weir Industrial Gateway in a generic sense ie independent of product type.

Read this manual carefully before installing and using the product.

1.2 Scope

The three main items covered in this guide are :

o Power supply Module : PSM o Main Processor Module : MPM o Remote Signal Processor : RSP

The important specifications of these devices and the basic installation process will be covered.

1.3 Target Audience

This document is directed towards maintenance fitters, technicians and any staff involved in installing this system.

1.4 Safety

1.4.1 Safety Terminology and Symbols

You must observe the instructions contained in this manual. Failure to do so could result in damage to equipment and/or injury or death.

1.4.2 User Safety

Use Personal Protective Equipment (PPE) according to the site regulations for that work area. This may include, but is not limited to:

o Hard hat o Safety goggles o Protective shoes o Protective gloves o Hearing protection

Notice:

Never work on equipment unless the correct lockout procedures have been followed

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

1.4.3 Warnings

WARNING: THE SAFETY OF ANY SYSTEM INCORPORATING THIS EQUIPMENT IS

THE RESPONSIBILITY OF THE ASSEMBLER OF THE SYSTEM.

WARNING: TO PREVENT FIRE OR SHOCK HAZARD, DO NOT OPEN COVERS. NO

USER SERVICEABLE PARTS INSIDE. REFER SERVICING TO QUALIFIED SERVICE PERSONNEL.

WARNING: EXPLOSION HAZARD. DO NOT CONNECT OR DISCONNECT CABLES

WHEN ENERGIZED IN A HAZARDOUS LOCATION ENVIRONMENT. DO NOT CONNECT OR DISCONNECT ANY CABLES WHILE CIRCUIT IS LIVE OR ULESS THE AREA IS FREE OF IGNITABLE CONCENTRATIONS.

WARNING: IN HAZARDOUS LOCATION ENVIRONMENTS THE EQUIPMENT MUST

BE OPERATED AT ALL TIMES WITH THE CONNECTOR SHROUDS INSTALLED.

WARNING: DISCONNECTING CABLES IN A HAZARDOUS LOCATION

ENVIRONMENT CAN CREATE A SPARK. CABLES ARE ONLY TO BE DISCONNECTED BY QUALIFIED SERVICE PERSONNEL.

AVERTISSEMENT: LA SÉCURITÉ DE TOUT SYSTÈME INCORPORANT CET

ÉQUIPEMENT EST LA RESPONSABILITÉ DE L'ASSEMBLÉE DU SYSTÈME.

AVERTISSEMENT: POUR ÉVITER LE RISQUE D'INCENDIE OU DE CHOCS, NE PAS

OUVRIR LES COUVERTURES. AUCUNE PIÈCE DE SERVICE UTILISABLE À L'INTÉRIEUR. CONSULTER L'ENTRETIEN AU PERSONNEL DE SERVICE QUALIFIÉ.

AVERTISSEMENT: RISQUE D'EXPLOSION. NE PAS CONNECTER OU

DÉCONNECTER DES CÂBLES QUI SONT ENERGISÉS DANS UN ENVIRONNEMENT DE LOCALISATION DANGEREUSE. NE PAS CONNECTER OU DÉCONNECTER TOUS LES CABLES, SI LE CIRCUIT EST VIVANT OU ULTÉRIEUR, LA ZONE EST LIBRE DE CONCENTRATIONS IGNITABLES.

AVERTISSEMENT: DANS LES ENVIRONNEMENTS DE LOCALISATION

DANGEREUSES, L'ÉQUIPEMENT DOIT ÊTRE FONCTIONNÉ À TOUTES LES HEURES AVEC LE CONNECTEUR SHROUDS INSTALLÉ.

AVERTISSEMENT: LA DÉCONNEXION DES CABLES DANS UN ENVIRONNEMENT

DE LOCALISATION DANGEREUSE PEUT CRÉER UNE SPARK. LES CABLES SONT SEULEMENT DÉCONNECTES PAR UN PERSONNEL DE SERVICE QUALIFIÉ.

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Part No

Varistor Voltage (V)

Maximum Allowable Voltage

Clamping Voltage At 8/20µs Max (V) Ip (A)

Maximum Peak Current at 8/20µs (A) 1 time 2 times

Panasonic

ERZ-V20D431

430 (387 to 473)

275Vac, 350 Vdc

745 5 800

600

710

1750

1250

710

3500

2500

710

3500

2500

710

6000

4500

710

100

10000

6500

1.4.4 Determination That Equipment Can be Used Safely in the Intended Area

The installation of this system requires that the equipment be mounted in such a way that it can withstand impacts from use and vibration from the machinery it is attached to. The following should be checked to ensure that the installation is safe:

 Cables should be supported such that the supports carry the weight of the cable and

the connectors are not being pulled from the weight of the cable.

 In hazardous location areas, the air surrounding the equipment should have an

oxygen concentration of not greater than 21 percent by volume; and a pressure of 80 kPa (0.8 bar) to 110 kPa (1.1 bar)

 The ambient temperature range is from -30°C ≤ Tamb ≤ 70°C.  The mains that the equipment is attached to have a 15A circuit breaker installed

outside of the hazardous area for hazardous locations.

 All connections are tight and in hazardous location areas, all locking mechanisms on

the connectors are attached.

 All connections are watertight, with Nitto No 15 self-amalgamating tape used on the

RF connections to ensure that water cannot get into the connector.

 The sensors are installed in such a manner that they will not come off from operation,

and the sensor cables will not interfere with equipment operation. It is preferable that sensor cables do not get very close to electric motor windings, which can generate significant amounts of magnetic field, which may affect the sensor sensitivity.

 The sensor electrical connections are waterproof.

The transient limiting of lightning, surges, and other transients coming from the mains power is done within the power supply by the use of transient/surge absorbers. These are connected line to line, as well as line to chassis ground. The characteristics of these transient absorbers are as follows:

The Continuous operating temperature of the gaskets are as follows:

Figure 1-1 Transient Protection Parameters, Line to Line and Line to Ground

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Name

Acronym

Description

Power Supply Module

PSM

24Vdc 500W power supply for MPM, able to supply fully loaded system at extremes of environmental ratings

Main Processor Module

MPM

Module that runs the Node Engine software, processes data & connects to the enterprise

2 Transportation and Storage

2.1 Consignment receipt and unpacking

o Inspect the package for damaged or missing items upon delivery. All items

should be checked against the delivery note

o Note any damaged or missing items and inform the supplier and relevant

parties

2.2 Transportation Guidelines

o The gateway and its components are designed to be lifted and man-

transported without cranes or other lifting equipment

2.3 Storage

For long term storage, ensure connector caps are firmly secured on the all gateway connectors

3 System components

A number of main components are common across many of the product implementations. These are :

o Power Supply Module (PSM) o Main Processor Module (MPM) o Remote Signal Processor (RSP)

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Remote Signal Processor

RSP

Device that interfaces with sensors on the equipment

Junction Boxes

Various

A number of junction boxes and cables are used to connect the RSP to sensors on the equipment, example shown to right

WiFi Antenna (2.4GHz)

Default WiFi antenna (2.4GHz) 6dB Omnidirectional (Mobilemark)

Cellular Antenna

Default Cellular band Antenna 9dB Omnidirectional (Mobilemark)

WiFi Antenna (2.4GHz/5GHz)

Dual Band Operation (Laird)

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Main Processor Module

(MPM)

Power Supply Box

(PB)

24VDC

RSP

Qpro

Sat/GPS

Sensor

ECA_MR_nn

24VDC, LAN

ECA_RS_nn

Analog

ECA_MQ_01

24VDC, S erial

ECA_PM_01

24VDC

WIFI

Module

ECA_MW_01

POE

Along with these are a range of standard cables that connect these main components to the sensors on the equipment.

54 System architecture

The Weir Industrial Gateway MPM & RSP system is arranged in a modular manner shown in the figure below.

Figure 4-1 System diagram

o MPM can support 4 x RSPs directly wired via Ethernet o PSM is rated to support MPM + 4 x RSPs + all other optional items o Each RSP is located near a piece of equipment being monitored while the

MPM may be remotely located with a maximum of a 100m cable run. Option to have RSP connected to the MPM via an external WiFi module but this arrangement requires a local 24Vdc supply to the RSP.

o Qpro amd WiFi module are optional items and not covered in this guide

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Comment [CS1]: Is this a Sanmina part# ?

65 PSM – Power Supply Module

The PSM is a switch mode power supply that operates of mains AC power and provides the 24Vdc that the whole system operates from.

6.15.1 Parameters relevant to installation and operation

o Model # : SPSM-000001 o DELL SKU : IP67IPS500-24 o Supply : 90 to 264 VAC, 47 to 400 Hz o Output: 20A@24Vdc (Nominal 500W) o IP rating : 67 o IK rating : 09 o Hazloc : Certified for Class 1 Div 2 environment o Temperature range (operating) : -30°C ≤ Tamb ≤ 70°C o Mass : 1.587kg o MTBF : > 500,000 hours o Casing material : Powder coated die cast aluminium o Mounting orientation : Connectors facing downwards

Figure 5-1 Iso view of PSM

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

J1 – AC

Power in

J2 DC

Power out

Figure 5-2 PSM Connectors

The cables provided with the power supply are as follows: AC Cable: PN# LFS04876 connects to the 3 pin port marked "power in". DC Cable: PN# LFS04875 connects to the 4 pin port marked "power out".

6.25.2 Installation

Physical installation of the PSM is covered in section 6.4. Electrical installation must include a current limiting device (fuse or circuit breaker) rated to protect the AC supply cable connected to J1. This circuit breaker should be rated to 15A.

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

76 MPM – Main Processing Module

The primary functions of the MPM are:

- Run the Node Engine application(s) required for each piece of equipment

o Convert signals captured by the RSP or other devices into TAG Metrics o Perform secure authentication with the Synertrex Enterprise o Provide remote access mechanism to allow diagnosis and analysis of issues

on site

The MPM is housed in a rugged enclosure fitted with signal conditioning, data acquisition, data processing and cloud interfacing systems.

7.16.1 Parameters relevant to installation and operation

o Supply : 14.6A@24Vdc o IP rating : 66 o IK rating : 09 o Hazloc : Certified for Class 1 Div 2 environment o Temperature range (operating) : -30°C ≤ Tamb ≤ 70°C o Mass : 16.7 kg / 36.8 lb o Casing material : Powder coating over allodyned aluminium o Mounting orientation: On vertical plate/wall with all connectors facing down

7.26.2 Images

Figure 6-1 MPM perspective view (cables and protective shroud removed)

The Weir Group PLC Weir Industrial Gateway setup guide rev 0.5

Figure 6-2 MPM with connector shroud installed

Connector shroud must be installed at all times once connectors are in place to prevent slurry/mud etc getting onto the connectors AND to meet hazardous location standards.

Figure 6-3 MPM connector view - protective caps installed

Connector caps shown are to be left installed for all connectors without a cable assembly attached. This is required for hazardous location approvals.

+ 36 hidden pages

Weir Group Management Services STXMPM Operators Guide

Specifications and Main Features

Frequently Asked Questions

User Manual