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Rapidlogger User Manual (English)

       

4    Installation Section

4.1   Installation in hazardous Areas

The installation of hazardous area ATEX certified equipment shall be done in accordance with the latest applicable edition of EN 60079-14. For overall installation details see installation drawing in Appendix A.

Rapidlogger Installation

The summary illustration above shows that the installation of the Rapidlogger System in the hazardous areas involves installing certain components in the safe area and some components in the hazardous area.  The installation of the ATEX certified Rapidlogger System can only be done by electrical installers that are properly certified to work in the specific area.  These certifications are specific to the countries where the installation is taking place.

4.2   Mounting the Rapidlogger Panel

The Rapidlogger panel has been designed to be installed and used in harsh environments.  The unit will operate well in direct sunlight, rain and sea water spray; however, protecting it from the elements will extend its life and maintain the appearance.  Installation will vary slightly depending on weather the single box unit or the double boxed outdoor unit is being installed.

Installation of the Outdoor double box unit

The double boxed Rapidlogger unit is the more common assembly that is supplied.  This consists of metal Rapidlogger unit enclosed inside a larger polycarbonate box with a clear front.  The secondary enclosure provides a very high degree of protection to the electronics in the unit from rain, dirt, physical damage, and pressure wash sprays.  An illustration of this unit and a multi voltage power supply appears below.

Rapidlogger Installation Double Box Unit

The first step in the installation is to identify an appropriate mounting location on the equipment to mount the Rapidlogger and the power supply.  Next place the unit in the spot to be mounted and mark the location of the four mounting holes with a center punch, make sure that the unit is level.  Drill holes in the panel with a drill bit sized for ¼” clearance (9/32” would be appropriate).  Next do the same for the holes for the power supply unit.  Use the supplied (2” long 1/4"-20 size socket head) bolts and lock nuts to fasten the unit to the control panel.  Do the same for the power supply unit.  Next route the power and sensor cables as needed around the equipment and connect them to the power source and the sensors.  All required cables come prewired to the unit generally only minimal wiring has to be performed.

Installation of the Single boxed unit

If installing a single boxed Rapidlogger unit follow these instruction and steps.  An illustration of the regular unit appears below.

Rapidlogger Installation Single Box Unit

If you need to remove the hinged Rapidlogger lid from the back of unit to install then the keypad cable needs to be detached.  This can be done by carefully detaching the keyboard cable from the unit lid by depressing the small locking tab (1) on the keypad connector and gently pulling and rocking the connector back and forth.  The mounting holes (2) used to mount the unit to a control panel are visible once the lid has been opened.

Rapidlogger Installation  Cut Away Unit Open Mounting Points of Interest 

Find a place on the panel to mount the Rapidlogger panel.  Place the unit in the area to be mounted and mark the location of the four mounting holes with a center punch.  Drill the holes in the panel with a 1/4"drill bit.  If you want to route the cables using the rear cable exits on the Rapidlogger then you must drill holes to clear the cable and cord grips also.  Thread the cables through the holes, and use the supplied (10-24 size) bolts and nuts to fasten the unit to the control panel. 

If the unit is to be powered with a 12/24V DC supply then the DC power cable should be installed at this time.  If the unit is to be powered from a 110/240V AC power supply then the power supply should be installed near the panel at this time.  The internal wiring of the power cable is done at the factory and the positive and negative wires go to main terminal block JB1-1 and 2 respectively.  A 1-Amp fuse (13) for the unit is located on the bottom left corner of the main circuit board.

Rapidlogger Installation  Wire Terminals

Rapidlogger Installation Wire Terminal Layout

 

Wire Terminal Layout

Installation of the Hazardous Area Barrier box

The hazardous area barrier box (if included) needs to be permanently mounted on a vertical surface.  The box can be mounted in either orientation (long side vertical or short side vertical).  For electrical details of the mounting refer to the installation drawing included in the Appendix A and the latest applicable edition of EN 60079-14 standard.

The fuse sizes and must be followed.  The Rapidlogger ATEX system utilizes a 1 ampere fuse.  Do not substitute with a larger value.  In case the fuse blows repeatedly, the source of the problem needs to be found and corrected instead of simply utilizing a larger fuse.

 

4.3   Interfacing to a Pressure Transducer

The cement pumping pressure is measured by means of a pressure transducer interfaced to one of the system's four high resolution analog inputs.  All four analog inputs support 4-20mA signal inputs and both 2 and 3 wire sensors.  Based on factory standard programming the pressure transducer is interfaced to the first analog input on the system (mA1).   All sensors are wired in to the terminal block JB1.  For a 2 wire 4-20mA sensor the mA+ wire from the sensor should be connected to JB1-3 and the mA- signal wire from the transducer is connected to JB1-12. 

All of the manufacturer installation instructions for the pressure transducer should be followed in order to retain the ATEX certification.

Pressure Sensor Monitoring                             Pressure Sensor Software

4.4   Interfacing to a Densitometer

Many modern cement units are equipped with a Coriolis type densitometer (Micro Motion, Endress+Hauser, etc).  These densitometers can measure the flow-rate, volume, and density of the treatment fluid.  The output from the densitometers is generally in the form of an analog output for density and a frequency output for the treatment rate and volume.  These signals can be interfaced to the Rapidlogger unit and the data can be displayed and recorded.

The Micro Motion densitometer outputs density on its first 4-20mA output.  Based on factory standard programming the density is interfaced to the second analog input (mA2) of the Rapidlogger.  The mA+ wire from the densitometer transmitter should be connected to JB1-4 and the mA- signal wire from the transmitter to JB1-13.

Flowmeter Software                      Flowmeter Monitoring

The Micro Motion densitometer outputs flow rate on one of its frequency output channels.  This output is read into the Rapidlogger using one of its frequency inputs.  The total volume is calculated and displayed by the Rapidlogger based on the total number of frequency pulses on this same channel.   Based on factory standard programming the flow rate from the densitometer is interfaced to the first quadrature input (QA1).  The FO+ (Frequency Ouput +) wire from the densitometer transmitter should be wired to JB1-16 and the FO- (Frequency Output -) wire to one of the available DC ground outputs such as JB1-7.

All of the manufacturer installation instructions for the densitometers should be followed in order to retain the ATEX certification.

4.5   Interfacing to pump stroke sensors

Pump stroke sensors are proximity switches that sense the rotation of some rotating part of a pump.  Both 2 and 3 wire type proximity switches (14) ranging from 12-24V can be interfaced to the Rapidlogger.  Based on factory standard programming the pump stroke counter 1 is interfaced to the first frequency input (F1) of the Rapidlogger.  It is generally not recommended to use Mag pickups with the Rapidlogger since the weak signal from them can cause loss of pulses over long cable runs.

Proximity Sensor Software

The frequency output wire from the proximity switch should be wired into to JB1-20.  The output from the second pump stroke counter should be wired to (F2) JB1-21.

All of the manufacturer installation instructions for the inductive proximity sensor should be followed in order to retain the ATEX certification.

4.6   Interfacing to Load cells

Tension and compression on slickline, wireline and coiled tubing units are measured by means of load cells.  4-20 milli ampere type load cells can be used with the Rapidlogger system.  It is possible to use compression, tension, or bi-directional load cells with the Rapidlogger.  Based on factory standard programming the load cell is interfaced to the first analog input on the system (mA1).   All sensors are wired in to the terminal block JB1.  For a 2 wire 4-20mA load cell the mA+ wire should be connected to JB1-3 and the mA- signal wire to JB1-12.  The second load cell or pressure transducer can then be connected to the second milli ampere input on the system and so on.

All of the manufacturer installation instructions for the load cell should be followed in order to retain the ATEX certification.

 

Load Cell Software               Load Cell Monitoring

 

4.7   Placing ATEX equipment in to service

Before powering up the system an inspection in accordance with EN 60079-17 latest applicable edition should be conducted.  Notably it needs to be verified that all the cables glands and connectors are properly installed and sealed.  No special adjustments are needed before startup.  Once the safety inspection in accordance with EN 60079-17 is complete the unit can be powered up with the power switch. 

The first power up must not be conducted in the presence of any hazardous atmospheres.  In case a fuse blows immediately power down the system and locate the source of the fault before replacing the fuse and attempting to power up again.

Continue to Section 5.0 Maintenance

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