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USER`S MANUAL - The M.C. Miller Company

1. Start Date ccyymmdd Example shows Oct 27 2004 E End Date ccyymmdd Example shows Nov 02 2004 Nn PA NORMAL parameter in hex Normal GPS Reacquisition Settings Bb PA BACKUP parameter in hex GPS Reacquisition Settings if Normal Reacquisition fails Ti PA INITIAL parameter in hex Time Modes for non cycling periods 48 More details are presented below regarding the codes for the Advanced Settings as displayed on the above LCD screen Advanced Settings Codes Depicted in the V CA Screen The Advanced Settings codes that are depicted in the V CA screen relate to the settings that you downloaded from your PC or Laptop for the GPS Reacguisition Parameters and the clock mode options you selected for each of the non cycling periods in your application GPS Reacguisition Parameter Codes Nn PA NORMAL parameter in hex Bits n 3 to n O LSBit Normal Time elapsed since the last GPS reacguisition attempt 3 2 1 0 Hex MYAWS LENDAN S 1 Parameter value 3 hour Default GPS reacguire at least every 3 hours Never Used for testing purposes only Reacguisition goes to Backup Parameters 0 5 hour Not recommended used for testing purposes only 1 0 hour Not recommended used for testing purposes only 1 5 hour Not recommended used for testing purposes only 2 0 hour Better accuracy than 2 5 hour but more battery drain 2 5 hour Better accuracy than
2. 3 0 hour but more battery drain 3 0 hour Default Depending on use may be optimum Drain versus Accuracy 6 hour Used for Power savings and when accuracy can be relaxed a bit 8 hour Used for Power savings and when accuracy can be relaxed a bit 10 hour Used for Power savings and when accuracy can be relaxed a bit 12 hour Used for Power savings and when accuracy can be relaxed a bit 24 hour 1 day Used when accuracy can be relaxed 48 hour 2 days Used when accuracy can be relaxed 96 hour 4 days Used when accuracy can be relaxed 192 hour 8 days Not recommended used for testing purposes only Bits N 3 MSBit to N 0 Absolute value of Temperature change since the last GPS reacguire 3 2 1 0 Hex 0 TMU A mpooaoukwrnir Parameter value 15 Celsius Default Unlikely change but it is there if it happens 0 Celsius Not recommended Continuous GPS Reacquiring 0 03 Celsius Not recommended used for testing purposes only 0 06 Celsius Not recommended used for testing purposes only 0 12 Celsius Not recommended used for testing purposes only 0 24 Celsius Not recommended used for testing purposes only 0 49 Celsius Not recommended used for testing purposes only 0 97 Celsius Not recommended used for testing purposes only 1 9 Celsius Not recommended used for testing purposes only 3 9 Celsius Not recommended may be too much battery drain 7 8 Celsius Greater accuracy than 15C May be too much
3. CRONOS CURRENT INTERRUPTER WITH INTEGRAL GPS RECEIVER FOR ACCURATE CLOCK SYNCHRONIZATION USER S MANUAL Version 10 IMIG MILLER c M C Miller Co Inc 11640 U S Highway 1 Sebastian FL 32958 U S A Telephone 772 794 9448 Website www mcmiller com MANUAL CONTENTS Page SECTION I INTRODUCTION I 1 Basic Operation of the Cronos Unit reeeereee veena 3 I 2 The Two Operational Clock Modes of the Cronos Unit 6 I 3 How to Shutdown amp Reset the Cronos Unit and How to Wake Up the LCD Screen ccccee eee enue 7 Es Calibration s iorno orrie E S EEE 9 SECTION II HOW TO PROGRAM THE CRONOS UNIT FOR YOUR APPLICATIONS 11 1 Initial Procedures scris sitke swarwasvdescasegeeaisactdsdvdeawieus 9 II 2 Howto Make Application Settings Selections 10 I 3 Howto Make Advanced Settings Selections 16 I 4 How to Download your Programmed Settings from your PC or Laptop to your Cronos Unit or Units sesccsssecssessss 25 SECTION III HOW TO USE THE ONBOARD KEYPAD III 1 How to View All Programmed Settings and How to Change Some Settings via the Kevpadssmussuamssaudaud 26 II 2 How to Upload Programmed Settings from a Cronos Unit to Another Cronos Unit osava tiimita aia pakase emt 30 III 3 How to Clock Sync an MCM JR Current Interrupter Using ALO HO OS senta sagedmteus tule onne mia isiku ka maa 31
4. WiDAY Screen V DAY 12 30a NL CL E 05 30p V View Only DAY Daily Cycle Time Parameters for Night Latch NL CL Night Latch State is Relay Closed Other Option NL OP Night Latch State is Relay Open S Start Cycle time Format hour minute a am or p pm 12 30 am shown E End Cycle time Format hour minute a am or p pm 5 30 pm shown V SYN screen V SYN SS 00 00a SSW CL STM UTC V View Only SYN Synchronization Parameters SS 00 00 a Synchronize start of waveform every day at 00 00 am 47 Other Option Synchronize at Start of Cycle Time Format hour minute a am or p pm SSW CL Relay State at Cycle Start Shows Start Cycle with Switch Closde Other Option Start Cycle with the Switch Open SSW OP STM UTC System Time is UTC Coordinated Universal Time Other option System Time mode 1s GPS STM GPS V TO screen YEO OTC 00076A L 8A CTO 000C18 V View Only TO Time Offsets to Delay or advance the actual change in Switch state OTC Open to Close Delay in hex sign and magnitude Formatted value Showing MCM defaults CTO Close to Open Delay in hex sign and magnitude Formatted value Showing MCM defaults L User selected Local Offset Sample shows 5 0 BA US Eastern Time See Section II for more details on the Delays and Local Offsets V CA screen VCA 520041027 NnBbIi E20041102 V View Only CA Calendar Mode and some Advanced Settings parameters S
5. 1Hz Started at 7 00am 09 34 am 0 067 ACQUIRE 59 450 3 963 0 0220 Acquisition while Cycling 09 38 am 3 000 CY 1 088 3 264 0 0181 Continue Cycle 1Hz 12 38 am 0 067 ACQUIRE 59 450 3 963 0 0220 Acquisition while Cycling 12 42 am 3 000 CY 1 088 3 264 0 0181 Continue Cycle 1Hz 03 42 pm 0 067 ACQUIRE 59 450 3 963 0 0220 Acquisition while Cycling 03 46 pm 1 233 CY 1 088 1 342 0 0075 Continue Cycle 1Hz till 5 00pm 05 00 pm 0 100 CL SAT 0 873 0 087 0 0005 Relay CLOSED Sat time 05 06 pm 6 900 CL 0 110 0 759 0 0042 Night Latch State APX time 0 1607 of available energy consumed on a weekday 37 Calculated Energy Consumption during Saturdays and Sundays non cycling days Ref Time Elapsed Operating Power Energy Used Comments hh mm a pm Time H Condition mA mA H 00 00 am 24 000 CL 0 110 2 640 0 0147 Night Latch State APX time 0 0147 of available energy consumed on a weekend day Calculated Daily Energy Consumption Averaged Over a 7 Day Week Average Daily 5 Mon Fri 2 Sat Sun 7 0 1190 of available energy Calculated Lifetime of the Main Battery System Decimal Days 100 Average Daily 841 useful days b Unit Running on Emergency Battery Calculated Energy Consumption over the course of a Weekday Mon thru Fri Ref Time Elapsed Operating Power Energy Used Comments hh mm a pm Time H Condition mA mA H 00 00 am 6 500 CL 0 119 0 774 0 0774 Night Latch State APX time 06 30 am 0 067
6. ACQUIRE 53 200 3 547 0 3547 Acquisition 30 mins before target 06 34 am 0 433 CL SAT 0 812 0 352 0 0352 Relay CLOSED Sat time 07 00 am 3 000 CY 0 942 2 826 0 2826 Cycle 1Hz Started at 7 00am 09 34 am 0 067 ACQUIRE 53 200 3 546 0 3546 Acquisition while Cycling 09 38 am 3 000 CY 0 942 2 826 0 2826 Continue Cycle 1Hz 12 38 am 0 067 ACQUIRE 53 200 3 547 0 3547 Acquisition while Cycling 12 42 am 3 000 CY 0 942 2 826 0 2826 Continue Cycle 1Hz 03 42 pm 0 067 ACQUIRE 53 200 3 546 0 3546 Acquisition while Cycling 03 46 pm 1 233 CY 0 942 1 162 0 1162 Continue Cycle 1Hz till 5 00pm 05 00 pm 0 100 CL SAT 0 812 0 081 0 0081 Relay CLOSED Sat time 05 06 pm 6 900 CL 0 119 0 821 0 0821 Night Latch State APX time 2 5853 of available energy consumed on a weekday 38 Calculated Energy Consumption during Saturdays and Sundays non cycling days Ref Time Elapsed Operating Power Energy Used Comments hh mm a pm Time H Condition mA mA H 00 00 am 24 000 CL 0 119 2 856 0 2856 Night Latch State APX time 0 2856 of available energy consumed on a weekend day Calculated Daily Energy Consumption Averaged Over a 7 Day Week Average Daily 5 Mon Fri 2 Sat Sun 7 1 9283 of available energy Calculated Lifetime of the Main Battery System Decimal Days 100 Average Daily 52 useful days Application Example 2 In this example application the unit is running in the Scheduled start and stop time mode indefin
7. H is the Daily average Runs for 10 months 10 30 0 48 144 mA H during the Shut Down Days Third calculate the Average Daily Energy mA H consumed in one year Average 1152 144 365 3 55 mA H Daily Average for the year Finally how many days will the battery last for this example application Using the Emergency 9v Lithium battery assuming 1000mA H 281 days 9 months 41 APPENDIX 2 HOW TO INTERPRET THE DATA DISPLAYED ON THE LCD Since a significant amount of power is required to operate the LCD located on the front panel of the Cronos unit the LCD will shut itself off automatically when there is no keypad activity The Cronos unit however will continue to function as normal even though the LCD is shut down The LCD will shut itself down after 10 minutes of inactivity on the keypad You can wake up the LCD by pressing for a brief moment on the push button on the front panel As discussed in Section HI 1 by pressing on the various buttons on the keypad different information data will be presented on the LCD The purpose of this Appendix is to provide a section in the User s Manual to which you can refer when necessary to interpret the data displayed on the various LCD screens that will appear when you press the various keypad buttons a Main Screen The Main Screen will be displayed when you press any of the Operating Mode buttons on the keypad The labels on the buttons are co
8. Interrupt Cycle field continuously 24 hours a day 7 days a week This mode selection will override the Night Latch selections and any Disable Interruption On selections skip days you might have made in a previous application In other words the Cronos unit will never go into the sleep state during the Continuous cycling mode of operation By selecting the Relay always closed rectifier on mode or the Relay always open rectifier off mode you would be electing to disable current interruption and you would be employing the Cronos unit to provide either a continuous short circuit CP current ON situation or a continuous open circuit CP current OFF situation Finally in the Shutdown mode no power is supplied to the relay and the enhancement mode MOSFET switches will be in the OFF state Since current cannot flow through the MOSFET switches while in the OFF state the relay will be continuously in the OPEN state in the shutdown mode This is the mode in which your Cronos unit should be programmed for transportation or when the unit is not in use for prolonged periods of time Note Since the relay will be in the OPEN state while the unit is in the shutdown mode the Cronos should not be left connected to a rectifier while in this mode as CP current will not be able to flow through the relay Interruption Cycle Field You can select from 5 pre programmed current interru
9. SECTION IV HOW TO CHANGE THE BATTERIES IN THE CRONOS UNIT imettvnnv aavu teest 32 Appendix 1 Battery Life Versus Programmed Settings 36 Appendix 2 How to Interpret the Data Displayed on the LCD a Main Screen sack nie aa atlase 42 b Select Cycle Number Screen 46 c View Only Screens s ad 47 d View amp Enter Screen 51 SECTION I INTRODUCTION 1 1 Basic Operation of the Cronos Unit Current interrupter devices consist of two basic elements namely a control system and a relay The control system element controls the status of the relay which can only be in one of two positions namely Open or Closed When it is in the Closed position current is allowed to flow through the relay and when it is in the Open position current cannot flow through the relay The relay can be held in the Closed or Open positions or it can be switch repetitively between the Closed and Open positions which is the case during rectifier current interruption applications for example In such applications the relay switching from Closed to Open corresponds to the rectifier current switching from ON to OFF while the relay switching from Open to Closed corresponds to the rectifier current switching from OFF to ON With regard to rectifier current interruption applications the timing of the switching events is critical part
10. Start field corresponding to the number of days that you d like to delay the start of the current interruption process When the delay period is over the operating mode will automatically change to the Weekly cycling mode Note During the delay period the Cronos unit will be in its Night Latch sleep mode and the relay will typically be held in the closed position so that the rectifier current will always be ON during this delay time to keep the pipeline protected You should select the Closed rectifier on option in the Night Latch field if this is the desired case In the Weekly cycling mode the Cronos unit will start and stop current interruption each day of the week at the times you enter in the Night Latch field see below in the boxes labeled Start cycling and Stop cycling respectively If you would like to skip certain days of the week ie not have current interruption on certain days of the week for example Saturdays and Sundays you can place a tick by clicking in the appropriate box beside your selected skip days in the field labeled Disable Interruption On By selecting the Scheduled start and stop time mode you can enter in the Schedule field the calendar date you d like to start interrupting the rectifier current and the date you d like to stop interrupting the current As with the Weekly cycling mode you can select to start and stop curren
11. acquire the GPS signal for the first time will typically be somewhere between 16 and 19 minutes Use of Current or Previously Saved Position Data Option Position data from the GPS although computed and stored by the unit when a view of at least 5 satellites is available is not required to achieve satellite clock Cronos clock synchronization In fact so long as the Cronos unit can see at least one satellite satellite clock Cronos clock synchronization can occur However in cases where the satellite clock signal takes an indirect path to the Cronos unit for instance the signal may bounce off buildings en route to the Cronos unit a small time error can be introduced This time error can be mitigated however if position data can be employed by the Cronos unit Whether or not you instruct the unit to employ position data to generate a time error correction is determined by your setting selection on the Advanced Settings window under the description Special Position Accuracy Position Lock You can either select No or Yes for this setting If you select No which is the default setting the unit will not employ GPS position data This is the normal setting which can be used in all instances With this setting you do not have to worry about moving the Cronos unit to different locations and performing a system reset see Section I 3 at each new location since the unit does not e
12. battery drain 15 Celsius Greater accuracy than 31C Default for optimum accuracy drain Trade off 31 Celsius Unlikely change but it is there if it happens 62 Celsius May never change 62 degrees 125 Celsius May never to change 125 degrees 250 Celsius Will never change 250 degrees 49 Backup Retry to reacguire when in Approximate APX Time or when Normal GPS reacguisition attempts fail Bb PA BACKUP parameter in hex 1Byte B b 7 6 5 4 3 2 1 0 Contains the following parameter bits Bits 1 to O LSBit Backup parameters for the APX time mode while on continuous APX time 1 0 Bin Bits 4 to 2 4 3 2 Bin 000 001 010 011 100 101 110 111 Bits 7 to 5 7 6 5 Bin 000 111 Clock Mode Codes mode Parameter value 8 days Default Try to Reacguire GPS every 8 days while in APX time mode 4 days Try to Reacguire GPS every 4 days while in APX time mode 16 days Try to Reacguire GPS every 16 days while in APX time mode 32 days Try to Reacguire GPS every 32 days while in APX time mode Backup parameters for the GPS time mode Time before retry after a failed Reacguisition attempt satellite time mode Parameter value 2 hours Default Try to Reacguire GPS every 2 hours if Normal period failed 1 hour Try to Reacquire GPS every hour if Normal period failed 3 hours Try to Reacguire GPS every 3 hours if Normal period failed 6 hours Try to Reacquire GPS every 6
13. hours if Normal period failed 12 hours Try to Reacquire GPS every 12 hours if Normal period failed 1 day Try to Reacguire GPS every day if Normal period failed 3 days Try to Reacguire GPS every 3 days if Normal period failed Never days Never try to Reacguire GPS if Normal period failed The Never days option is recommended for special cases only Available Parameter value First available not used Last available not used The following codes pertain to whether the APX or the satellite time mode 1s selected for each of the non interruption periods of the application 1Byte T i 3 2 1 0 3 2 1 0 Contains the following parameter bits 1Byte Contains the following parameter bits Bit Value OPM Mode Description 10 0 Schedule Only APX for Night latch outside the Schedule Default 10 1 Schedule Only GPS for Night latch outside the Schedule 11 0 Schedule Only APX for Night latch inside the Schedule Default 11 1 Schedule Only GPS for Night latch inside the Schedule 12 0 Delay Only APX for Night latch Default 12 1 Delay Only GPS for Night latch 1 3 0 Weekly Only APX Night latch Default i3 1 Weekly Only GPS for Night latch 1 0 0 Close Only APX for the always Closed state Default 1 0 1 Close Only GPS for the always Closed state 1 1 0 Open Only APX for the always Open state Default 11 1 Open Only GPS for the always Open state 1 2 0 All but Shut Down 6 minute delay going from GPS to APX Defau
14. in association with particular programmed settings are presented in Appendix 1 As an example though with the GPS Reacquisition Parameters set as indicated in the above Advanced Settings window ie set at the default settings and with current interruption set to occur each and every day between the hours of 7AM and 5PM 0 8sec On 0 2sec Off cycle the battery life should be in the vicinity of 840 days which is well over 2 years In this example the GPS signal would be reacquired 4 times a day ie 4 times during each current interruption period for over 2 years It should be noted that the Cronos unit s first attempt to reacquire the GPS signal each day will occur one half hour prior to the start cycle time start time of the current interruption period This is so that the clock time will be precise before the start cycle time is reached which is particularly important when a number of current interrupter units are operating on rectifiers in a presumed synchronized fashion As can be seen from the tables in Appendix 1 the largest drain on the batteries occurs during a GPS signal reacquisition process Consequently if you reduced the time interval between reacquisitions to say 2 hours or 1 hour your battery life would be significantly less than 2 years in the above example On the other hand increasing the time interval between reacquisitions to say 4 or 5 hours would increase battery life however the clock accuracy woul
15. on the operating mode and especially on the GPS Reacquisition Parameters that are in effect during cycling and non cycling periods Under typical operating conditions certainly under our default settings conditions the main battery system should last for at least 2 years There is also a back up emergency battery in the unit that will supply power in the event that the main battery system should fail As described below you can also temporarily switch over to the emergency battery when you are in the process of changing out the main battery system The main battery system comprises two D cell Tadiran 5930 S 3 6Volt 19AHr Lithium batteries with an operating temperature range of 55 C to 85 C while the back up emergency battery is a 9Volt Transistor battery can be either Lithium or Alkaline We recommend that you make the process of replacing these batteries a routine part of your maintenance procedures For example battery replacement on a routine annual basis would be recommended To replace the batteries the following steps should be followed First disconnect the Cronos unit from the rectifier system and put the unit into Shutdown mode by pressing down the push button on the front panel continuously for at least 15 seconds Next wait for a period of at least 14 minutes to allow the unit to power down You can now access the batteries by removing the four screws located at the four
16. possible use of inappropriate previously saved position data it is recommended that you perform a system Shutdown and move the Cronos unit to the nearest location that will give the unit a view of at least 5 satellites perhaps on top of a building in order that appropriate position data can be saved and later used when the unit is back in its operational location Relay Delay Field You should think of this topic as Compensation for Relay Response Time Since relays have a finite response time we have provided the means for you to enter open to close and close to open delay times on the Advanced Settings window to compensate for the response times of your particular relay We have determined optimum delay values for the enhancement mode MOSFET switches that are used in the MCM relay and these values represent the default settings indicated under the Relay Delay field It is highly recommended that you do not change these values unless you are going to use another type of relay for example mercury switch relays which have different response times something on the order of 80ms or you are using the Cronos unit with an MCM relay MOSFET 23 based relay together with other current interrupters having other types of relays on the same pipeline The Relay Delay times are set so that power is supplied to the switches open to close or removed from the switches close to open at times tha
17. reacquire the GPS signal which as discussed in Section II 3 is a power consuming process This is a particular problem when the unit is inside of a vehicle or a building since the unit will try to reacquire the GPS signal for up to an hour at a time when it doesn t have a clear view of the sky In this case the main battery system could become fully depleted in a matter of weeks due to the excess power consumption In addition do not leave the Cronos unit in the JR Sync Req mode for longer than is necessary This is because the unit will be in the GPS 34 Tracking Mode Satellite Time Mode with this setting which again is the highest power consumption mode Immediately after performing a JR Sync process with an MCM JR unit you should make sure that the Cronos unit is cleared of this setting by pressing on the keypad button labeled Clear Reqs When this button is pressed the jr designation will be removed from the LCD screen and this setting will be cleared 35 APPENDIX 1 BATTERY LIFE VERSUS PROGRAMMED SETTINGS As was discussed in the main body of this manual primarily in Section II 3 battery lifetime is a function of the settings used to run the Cronos unit To illustrate this point we present below the results of calculations that were performed to estimate battery life under various settings conditions We first of all measured the power consumed current x voltage during the various states
18. show the cycle number 1 2 3 4 or 5 that is presently programmed This will be the interruption cycle number that you downloaded from your PC or laptop 28 These are the interruption cycle numbers discussed in Section II corresponding to the five pre programmed waveforms for current interruption Again the 5 pre programmed cyclic waveforms are as follows Cycle 1 0 7sec ON and 0 3sec OFF Cycle 2 0 8sec ON and 0 2sec OFF Cycle 3 1 5sec ON and 0 5sec OFF Cycle 4 4 0sec ON and 1 0sec OFF Cycle 5 10 0sec ON and 2 0sec OFF By pressing on the Up or Down buttons on the keypad you can select cycles through 5 Note You cannot change the specific ON and OFF times from the keypad you can only do so from your PC or laptop as described in Section II Note On a somewhat unrelated issue as indicated in Appendix 2 section b Select Cycle Number Screen when you press on the SEL CYC button in addition to viewing the cycle data on the LCD screen you will also see the code SATs where s can be a number or a letter This code indicates how much time has elapsed since the last successful acquisition of the GPS system The elapsed times corresponding to the various values of the s parameter are detailed under STAT in Appendix 2 section a Remote Monitoring of the Keypad LCD If access is difficult to the physical location of a Cronos unit for example you can view th
19. the sleep period Typically you would select the Closed rectifier on option in order to maintain cathodic protection of the pipeline during the night Relay State at Cycle Start Field Typically you would select to have the relay held in the closed state CP current allowed to flow state during non interruption periods see above and so the first transition to occur when current interruption begins would be a current ON to a current OFF transition In this case you would select the Relay Opens Rectifier switches Off at start of cycle option in this field The Relay Closes Rectifier switches On at start of cycle option would be selected if you had selected the relay to be held in the open state CP current not allowed to flow state during non interruption periods In this case the first transition to occur when current interruption begins would be a current OFF to a current ON transition II 3 Howto Make Advanced Settings Selections At this point you will have concluded making your Application Settings selections see above Section You can now if you wish make changes to the default settings that pertain primarily to the time mode that the Cronos unit will be operating under during non interruption periods APX time or satellite time and the GPS reacguisition parameters that will be in effect during interruption and non interruption periods In order to access these settings click
20. 03 20 cc Century number Note The Time and Date will display when time was never once acquired after Shut Down 4 Example shows the Approximate Time Mode Options Approximate time blank Satellite Time very precise a must for cycle operations Error Number List Except for a temporary Over or Under temperature error indication all other errors should never occur but they are listed here since the system is in constant self monitoring mode and since the possibility exist The following briefly describes the current Error Number ee interpretation when ERee appears in the STAT portion of the Main screen see above for details When Resetting System is mentioned it is implied that the Shut Down Mode was entered before waking up All reported errors below are latching errors they happened at least once while the system continuously monitors itself The system may run normally depending on the case after the error is reported The user however should correct the situation as soon as it is displayed ee 01 Battery too low for reliable operation At or below 4 7 volts Solution Check and or replace the battery allowing a full System Reset no power for greater than 30 seconds ee 02 Communications with the GPS Receiver failed or the Satellites send the wrong info Normally should never occur Solution A new GPS Acguisition or Resetting the System should clear this problem If not send th
21. 8y mA 6 8v CL 0 119 0 110 Switch Closed while in APX time LCD Off CL SAT 0 812 0 873 Switch Closed while in SAT time LCD Off CL SATLCD 3 100 3 189 Switch Closed while in SAT Time LCD ON CL SATRSLCD 6 120 6 150 Switch Closed SAT time LCD ON amp RS232 PC ON CY 0 942 1 088 Switch Cycling 1Hz LCD Off CY LCD 3 100 3 110 Switch Cycling 1Hz LCD ON ACOUIRE 53 200 59 450 Any Switch Mode during GPS Acquisition SD 0 020 0 020 Shut Down Mode LCD Off OP 0 120 0 112 Switch Open while in APX time LCD Off Application Example 1 In this example application the unit is running in the Weekly cycling mode indefinitely and we have selected to skip current interruption on Saturdays and Sundays We have also selected the following parameters Start Time 7 00AM Stop Time 5 00PM Mon thru Fri Cycle 2 0 8sec ON 0 2sec OFF Night Latch Relay Closed also Night Latch to operate in APX time GPS Reacquistion Rate Every 3 hours during current interruption period a Unit Running on Main Battery System Calculated Energy Consumption over the course of a Weekday Mon thru Fri Ref Time Elapsed Operating Power Energy Used Comments hh mm a pm Time H Condition mA mA H 00 00 am 6 500 CL 0 110 0 715 0 0040 Night Latch State APX time 06 30 am 0 067 ACQUIRE 59 450 3 963 0 0220 Acquisition 30 mins before target 06 34 am 0 433 CL SAT 0 873 0 378 0 0021 Relay CLOSED Sat time 07 00 am 3 000 CY 1 088 3 264 0 0181 Cycle
22. CM Cronos icon the window shown below will appear on your computer screen By making appropriate selections on this Configuration Application Settings window you can setup the conditions that you require for your present rectifier current interruption application H Cronos Configuration New Configuration Fle Cronos Operating Mode Relay State at Cycle Start Shutdown Rela Opens Rect ier switches OF at start of cycle Relay always closed rectifier on Relay Closes Rectiier switches On at start of cycle Relay always open rectifier off Delay fer x number of days then start Delayed Start Weekly cycling Delay Time days 0 Scheduled start end stop time Interupton Cycle Cronos Cycle fji Continuous cycing Disable Interrugtion On P Saturday Surday On Time sec 0 7 Off Time sect 0 3 Ff Morday Tuesday Wednesday M Thursday Schedule Stat 7 572005 Stop f 7 5 2006 X Time Zone Nighi Laich Local Dlfsst 5 T Step oycira 12 00 AM gt Start cycling 12 00AM Hold relay during the night Cosed rectiher onl Advanced Sattings C Open fiectfier off 10 30 lt Get Setlings rom Cronos Send Settings to Cronos Fot Comi Time Zone Field This is an important selection as the time displayed on the Liquid Crystal Display LCD of the Cronos unit will reflect your local time assuming that you have selected an appropriate value for the Local Offset para
23. LCD or to the relay and the unit is in its sleep mode Note Since no power is supplied to the relay and since the relay comprises enhancement mode MOSFET switches the relay will be in its OPEN state while in the Shutdown mode Consequently the Cronos unit should not be left connected to a rectifier while the unit is in the Shutdown mode if continuous cathodic protection is require on the pipeline You can wake up the LCD screen while the unit is in any of its Operating Modes by pressing down on the Single Push Button for a period of about 2 seconds By doing so you can view the status of the unit on the LCD screen see Section III and Appendix 2 Note By performing the Shutdown process followed by waking up the LCD you will have performed a system reset The LCD screen will power down while in any Operating Mode other than the Shutdown mode if there has been no keypad activity for 10 minutes in order to conserve battery power The LCD screen will power down in 2 minutes with no keypad activity in the Shutdown mode You can wake up the LCD at anytime by pressing down on the Single Push Button for a period of about 2 seconds I 4 Calibration The Cronos unit does not require to be regularly calibrated the same way that a voltmeter does for example The Cronos only needs to be inspected at the M C Miller facility if the unit fails to pe
24. anent calibration memory M1 EEP Device did not respond Should never occur Solution Send unit to MCM ee 98 Error in part of the Cronos s permanent configuration memory M2 EEP Should never occur at the user site Solution Send unit to MCM Note that this error may be a normal indication at MCM Configuration was not loaded at least once or values without an integrity checksum ee 99 Error in part of the Cronos s permanent calibration memory M1 EEP Should never occur at the user site Solution Send unit to MCM Note that this error may be a normal indication at MCM Cal factor was not computed in the Oven 45 b Select Interruption Cycle Number Screen By pressing on the button labeled SEL CYC on the keypad you can view and or change the interruption cycle number from 1 through 5 The LCD screen will show the cycle number 1 2 3 4 or 5 that is presently programmed These are the cycle numbers discussed in Section II corresponding to the five pre programmed waveforms for current interruption Again the 5 pre programmed cyclic waveforms are as follows Cycle 1 0 7sec ON and 0 3sec OFF Cycle 2 0 8sec ON and 0 2sec OFF Cycle 3 1 5sec ON and 0 5sec OFF Cycle 4 4 0sec ON and 1 0sec OFF Cycle 5 10 0sec ON and 2 0sec OFF By pressing on the Up or Down buttons on the keypad you can select cycles through 5 Note You cannot change the specific ON and OFF
25. are in the view mode you can step through various LCD screens which reveal various data concerning your present Operating Mode by pressing the Up and Down buttons For an interpretation of the data displayed on these and the other LCD screens please refer to Appendix 2 entitled Interpretation of the Data Displayed on the LCD 26 Although you can view all settings as described above you can only make a limited number of changes to the presently downloaded settings via the keypad Of course you can reprogram the Cronos with all new settings by using your PC or laptop as described in Section II or by using another Cronos unit see Section III 2 Please note that the VIEW amp ENTER and ENTER buttons shown above on the keypad currently do not have any functions associated with them How to Change the Operating Mode You can elect to change the Operating Mode of the unit via the keypad You can change the Operating Mode by pressing the appropriate button on the keypad The button labels are correlated below with the Operating Mode they represent see Section II for a discussion on Operating Modes 24 Relay always open rectifier off OPEN Relay always closed rectifier on CLOSE Delay for x number of days then start RUN DEL Weekly cycling RUN WEEK Scheduled start and stop time RUN CALEN Continuous cycling RUN CYCLE To change to a different Operating Mode you would press o
26. ario LCD Contrast Field The settings shown under the LCD contrast field should not be changed unless you are instructed to do so by MCM After you have made any selection changes or have decided to stay with the recommended default settings on the Advanced Settings window click on the OK button on the window which will return you to the Configuration Applications Settings window 24 You are now ready to download your programmed settings to your Cronos unit or units II 4 How to Download your Programmed Settings from your PC or Laptop to your Cronos Unit or Units After you have made your Application Settings selections and your Advanced Settings selections as described in Sections II 2 and II 3 you can download transfer these settings to a single Cronos unit or to multiple Cronos units one unit at a time The first step is to connect the serial data communications cable between your PC or laptop and the terminal labeled PC Interface on the front panel of the Cronos unit Note If you have the Microsoft ActiveSync program running you should disallow serial cable connection to the COM 1 Port as the COM 1 Port will be required for direct communication with the Cronos unit otherwise this Port would be tied up by ActiveSync Next select the COM 1 Port on the Configuration Application Settings window and click on the Send Settings to Cronos butt
27. ault settings by clicking on the pull down list arrows in the four boxes shown in the Advanced Settings window under the GPS Reacquisition Parameters field and clicking on your selections Again though any changes you make will impact the trade off between clock accuracy and battery life see below Time Mode Considerations As discussed in Section I 2 having the clock operate in the APX approximate time mode results in considerably less power consumption than having the clock operate in the satellite time mode GPS tracking mode Consequently whenever possible it is recommended that the clock operate in the APX time mode during situations when extremely precise times are 19 not reguired Other than for current interruption periods where the satellite time mode is reguired and is automatically selected the APX time mode can be your selection of choice In fact as indicated on the Advanced Settings window our default settings indicate that the clock should operate in the APX time mode for all time periods other than current interruption periods You can if you wish change the clock mode to the satellite time mode by checking the GPS box for any of the non interruption time periods listed However you will be trading off accuracy at non critical time periods against battery power consumption if you do so Clock Accuracy Versus Battery Life Considerations Some example calculations of battery life
28. ay Closed also Night Latch to operate in APX time GPS Reacguistion Rate Every 3 hours during current interruption period a Unit Running on Main Battery System First calculate the Energy mA H consumed During the Weekly runs Daily energy is the same value as that calculated in Example 1 21 4 mA H is the Daily average for the Week 0 119 0 01 18000 21 4 mA H Runs for 2 months 2 30 21 4 1284mA H during the Weekly runs Second calculate the Energy mA H consumed During the Shut Down Days Shut Down consumes 0 020 mA Shut Down Daily energy 24 0 020 0 48 mA H is the Daily average Runs for 10 months 10 30 0 48 144 mA H during the Shut Down Days Third calculate the Average Daily Energy mA H consumed in one year Average 1284 144 365 3 91 mA H Daily Average for the year Finally how many days will the battery last for this example application Using the 2 D cell batteries assuming 18000mA H 4601 days 12 years b Unit Running on Emergency Battery Firs t calculate the Energy mA H consumed During the Weekly runs Daily energy is the same value as the one calculated in Example 1 19 2 mA H is the Daily average for the Week 0 6428 0 01 3000 19 2 mA H Runs for 2 months 2 30 19 2 1152mA H during the Weekly runs Second calculate the Energy mA H consumed During the Shut Down Days Shut Down consumes 0 020 mA Shut Down Daily energy 24 0 020 0 48 mA
29. corners of the front plate and flipping over the front plate to reveal the batteries on the back side 32 While replacing the two D Cell batteries you can temporarily connect the emergency battery by switching over the connector from the position labeled 2 D CELLS to the position labeled 9V If you do so do not forget to switch the connector back to the 2 D CELL position so that the unit will be powered by the main battery system when you power it back up Alternatively you can replace the batteries without switching over the connector provided that you do so guickly After you have replaced the batteries you can reinstall the front plate and power up the unit if you plan to use it right away by pressing momentarily on the push button Battery Plate Illustration An illustration of the reverse side of the front plate is shown below The actual layout may vary with the particular model of Cronos unit however the basic features will be the same regardless of model number You can refer to the set of instructions for battery replacement that will be located on the battery plate as a reminder of the procedures outlined above 33 Important Notes It is highly recommended that you transport the Cronos unit in its Shutdown mode Also the unit should be stored in its Shutdown mode This is due to the fact that in all operating modes other than the Shutdown mode the unit will try to
30. d decrease in this case A GPS signal reacquisition interval of 3 hours results in a clock accuracy on the order of 1ms and as 20 indicated by the above example results in long battery lifetimes which is why itis our default setting in this category Time Required to Reacquire the GPS Signal Considerations As indicated above the largest power drain occurs when the Cronos unit is in the process of reacquiring the GPS signal Obviously the shorter the time required to reacquire the GPS signal the better with a view to minimizing power consumption However the time period necessary for the reacquisition process to successfully occur depends on a number of variables As can be seen from Appendix 1 the battery life calculation examples used a GPS signal reacquisition time of 4 minutes 0 067Hr This would be a typical reacquisition time period under fairly ideal conditions which would include a clear sky few clouds and the Cronos unit having an unobstructed view of the satellites With a cloudy sky the time period for reacquisition of the GPS signal could be closer to 6 minutes for example If the unit does not have an unobstructed view of the satellites say the unit is inside a structure it could spend up to a maximum of 1 hour on each reacquisition attempt versus 4 to 6 minutes which would represent a considerable drain on the battery system Consequently it is important to test the unit s ability to acqui
31. e contents of the unit s LCD and hence observe the status of the unit remotely by running a serial data communications cable from your PC or laptop to the PC Interface terminal on the front panel of the Cronos unit You can view the unit s LCD by clicking on Cronos next to File on the Application Settings Configuration window of the Cronos software program described in Section II and clicking on Remote LCD Keypad This will pull up the unit s LCD Keypad displayed as a window on your computer screen as indicated below 29 G Remote LCD Keyboard MMMMMM 7 SWSuSTAT 02 39p 20030618 An interpretation of the data that will be displayed on the LCD screen which is shown in the above window above the Keypad is presented in detail in Appendix 2 Note It is highly recommended that you remove the serial data cable from the PC Interface terminal on the unit when not in use in order to conserve battery power III 2 Howto Upload Programmed Settings from a Cronos Unit to Another Cronos Unit You can upload transfer the settings data stored in one Cronos unit to a second Cronos unit via the keypad on the mother unit the first unit 30 First connect the serial data communications cable between the terminals labeled PC Interface on both Cronos units Next press on the button labeled UPLOAD Data Reg on the keypad of the mother Cronos unit This will result in
32. e the currents associated with the participating rectifiers would not be switched ON and OFF at exactly the same time In such cases the current waveforms would become out of phase with each other The ideal scenario is one in which current interrupter units can be left in the field for indefinite periods of time with no external power source reguired and their internal clocks will always be synchronized with each other during critical time periods such as periods of repetitive current interruption current cycling periods The Cronos Current Interrupter provides a solution to both the multiple unit clock synchronization problem as well as the no external power source reguired issue During critical time periods the clock in the control system of a Cronos unit is operated in the so called satellite time mode or GPS tracking mode When operating in the satellite time mode the unit uses a built in GPS receiver to acguire the GPS clock time and it synchronizes the internal clock with the GPS clock Since GPS satellites maintain highly accurate time the internal clock of the Cronos unit will keep highly precise time when operating in the satellite time mode see Section 1 2 for more discussion on the internal clock modes Furthermore since all participating Cronos units in a multiple unit application will operate in the satellite time mode during the same time periods synchronization of all of the internal clocks is assured duri
33. e unit to MCM for repair ee 03 High Temperature Limit Exceeded Unit was exposed to more than 85 Celsius Normally should never occur Solution Resetting the System should clear this error message assuming the unit is no longer subjected to temperatures greater than 85 Celsius Going outside the range a few degrees may cause a constant timing error proportional to the time the unit was outside the operating temperature range This timing error will clear itself on the next successful GPS acquisition Note that the LCD Display should not be stored at temperatures higher than 80 Celsius or operated at temperatures higher than 70 Celsius 44 The rest of the unit can operate continuously at 85 Celsius and for short periods of time at even higher temperatures If unit does not clear this error after Resetting the System and operating at lower temperatures for at least 3 minutes return the unit to MCM for repair ee 04 Low Temperature Limit Exceeded Unit was exposed to temperatures less than 40 Celsius Normally should never occur Solution Resetting the System should clear this message assuming the unit is no longer subjected to temperatures below 40 Celsius Going outside the operating temperature range a few degrees may cause a constant timing error proportional to the time the unit was outside the range This timing error will clear itself on the next successful GPS acguisition Note that the LCD display sho
34. ection I 2 when the Cronos unit is interrupting current the clock operates automatically in the GPS tracking mode satellite time mode as opposed to the APX approximate time mode As illustrated in Appendix 1 the Cronos unit consumes the most power while it is in the process of trying to reacquire the GPS signal Consequently the higher the frequency with which the unit tries to reacquire the GPS signal the more rapidly the battery power will be consumed 17 With regard to the clock operating in the satellite time mode you can select the time interval you d like to have between Normal reacguisition attempts as discussed below the default setting is 3 hours You can also select a temperature differential value the temperature difference between the present temperature and the temperature when the last reacguisition took place which when exceeded the unit will try to reacguire the GPS signal as discussed below the default setting is 15 C The purpose of the temperature differential selection is to minimize the impact of clock drift due to temperature changes Again you will be trading off clock accuracy with your settings selections against battery power consumption You can also select the time interval between reacquisition attempts that will take affect following any unsuccessful reacquisition attempt until a successful reacquisition is again made as discussed below the default setting is 2 hours After a fail
35. ed reacquisition attempt the unit will go into a different reacquisition schedule the Backup schedule corresponding to the setting you chose here and will only return to the Normal reacquisition schedule a reacquisition attempt every 3 hours in the default case after a successful reacquisition has occurred This is the Retry after x hours when in the GPS mode setting You can select the value for x by clicking on the pull down list arrow and highlighting your selection With regard to the clock operating in the APX time mode you can also select the time interval you d like to have between reacquisition attempts This would be the time between each attempt while in the APX time mode whether the attempts are successful or not You would make your selection by clicking on the pull down list arrow in the box labeled Retry after y 66 99 days when in APX mode and highlighting your selection for the y value We recommend that you at least begin with our default settings for the above parameters The default settings are indicated in the above Advanced Settings window and represent in our opinion the optimum compromise between accuracy and battery power consumption 18 With the default settings indicated in the Advanced Settings window the Cronos unit will try to reacguire the GPS signal every 3 hours during the current interruption period or when the unit sens
36. ell batteries assuming 18000mA H 4 342 days 12 years b Unit Running on Emergency Battery First calculate the Energy mA H consumed During the Schedule Days Daily energy is the same value as the one calculated in Example 1 19 2 mA H is the Daily average for the Week 0 6428 0 01 3000 19 2 mA H Runs for 1month 1 30 19 2 576 mA H during the Schedule Days Second calculate the Energy mA H consumed During the rest of the Schedule Days Keeping Approximate Time consumes 0 119 mA Note that Requiring every 8 days is negligible for our case Night Latch Daily energy 24 0 119 2 85 mA H is the Daily average Runs for 11 months 11 30 2 85 940 mA H during the other Days Third calculate the Average Daily Energy mA H consumed in one year Average 576 940 365 4 15 mA H Daily Average for the year Finally how many days will the battery last for this example application Using the Emergency 9v Lithium battery assuming 1000mA H 240 days 8 months Application Example 3 In this example application the unit is running in the Weekly cycling mode for 2 months each year and for the other 10 months each year the unit is in the Shutdown mode Also we have selected to skip current interruption on Saturdays and Sundays We have also selected the following parameters Start Time 7 00AM Stop Time 5 00PM Mon thru Fri Cycle 2 0 8sec ON 0 2sec OFF 40 Night Latch Rel
37. es that the temperature has changed by 15 C since the last reacguire time In addition if the unit is not successful with an attempt to reacguire the GPS signal the unit will go into its backup mode and will try to reacguire the signal at 2 hour intervals from that point on until there is a successful reacguisition at which point the unit will return to its normal reacguisition schedule a reacguisition attempt every 3 hours Furthermore when the unit is not interrupting current and the clock is operating in the APX time mode the unit will try to reacquire the GPS signal 8 days after any prior attempt to reacquire whether successfully accomplished or not By trying to reacquire and hopefully being successful in reacquiring the GPS signal at regular intervals every 8 days in our default example while in the APX time mode clock drift over long periods of time can be minimized For example if you set up a Schedule which calls for current interruption to begin in a month s time from the time you set up the Cronos unit for the application the unit will reacquire at least 3 times in the APX time mode prior to the scheduled start of the current interruption phase in order to help compensate for clock drift over the one month pre start phase of the Schedule We have built in a large margin for error however since we reacquire the GPS signal a half hour before a scheduled cycle start time You can change these def
38. icularly when a number of rectifiers having an effect on a section of pipeline under test are to be interrupted simultaneously In such cases the switching timing has to be as close to identical as possible on all of the current interrupter devices in the rectifier system A key component with regard to the timing of switching events in the case of a current interrupter is the internal clock which is part of the unit s control system As described in Section II the control system is programmed by the user for a particular application involving switching the relay between its Open and Closed states at various prescribed times over the course of a day or several days The control system once programmed with an application relies on the accuracy of its internal clock to run the program ie to cause the relay to switch at the programmed times Internal clock accuracy is of particular concern when current interrupters are to be employed on a number of rectifiers simultaneously In such cases the clocks in the participating units have to all be synchronized with each other With non GPS current interrupter devices in order to achieve clock synchronization all participating units have to be brought together in one place Furthermore because of clock drift due to local temperature variations and other effects the clocks in the participating current interrupter units can guite guickly drift out of synchronization in which cas
39. ime of 12 00 since 8 4 12 It should be noted that if the pipeline extends across a time zone to the west the local time in the next time zone to the west will actually only be 7 00AM when the Cronos units start interrupting the rectifier current However the Cronos units will all start cycling at the UTC time of 12 00 regardless of the actual local time in a particular time zone Operating Mode Field The various operating modes that can be selected for the Cronos unit are displayed in the Operating Mode field The various Operating Modes pertain to how the solid state relay will operate during your application Most typically you would employ the Cronos unit to switch rectifier current ON and OFF in a cyclic fashion over a period of time during the course of one day or perhaps for the same period of time each day for several days in succession When the solid state relay is in the closed position the enhancement mode MOSFET switches will be in the ON state and CP current will be allowed to flow The opposite is true when the relay is in the open position Consequently with the relay closed the rectifier current will flow or the rectifier current will be ON and with the relay open the rectifier current will not flow or the rectifier current will be OFF By selecting the Delay for x number of days then start mode you can enter a number from 1 to 9 in the Delayed
40. isition was between 5 1 2 days and 11 days ago C last successful acquisition was between 68 hours and 5 2 days ago B last successful acquisition was between 34 hours and 68 hours ago A last successful acquisition was between 17 hours and 34 hours ago s 9 last successful acquisition was between 8 1 2 hours and 17 hours ago s 1 to 7 means last successful acquisition was approximately s 64 minutes ago s 0 means last successful acquisition was less than 64 minutes ago 43 JPOK The system runs OK and in addition the JR sync that was selected is now running previous data may be used See the POK description below j OK The system runs OK and in addition the JR sync that was selected is now running POK The system runs OK but previous data may be used If the user moved the Cronos box containing the GPS antenna more than 200 feet since the last OK the user may need to restart from Shut Down See Recommended Configuration values If the user has NOT moved the Cronos more than 200 feet since the last OK then this POK indication is as good as the OK indication below It just means the System is seeing fewer satellites in the sky OK _ The system runs OK 02 30p Shows an example of the Time taking into account the Local Offset The p pm can change to a am 20030618 Shows an example of the Date in ccyymmdd format Example shows Jun 18 20
41. itely and we have selected to skip current interruption on Saturdays and Sundays Also the schedule involves weekly cycling for one calendar month each year For the other 11 months of each year the unit with be in the Night Latch mode with the relay closed and on APX time We have also selected the following parameters Start Time 7 00AM Stop Time 5 00PM Mon thru Fri Cycle 2 0 8sec ON 0 2sec OFF Night Latch Relay Closed also Night Latch to operate in APX time GPS Reacquistion Rate Every 3 hours during current interruption period 39 a Unit Running on Main Battery System First calculate the Energy mA H consumed During the Schedule Days Daily energy is the same value as the one calculated in Example 1 21 4 mA H is the Daily average for the Week 0 119 0 01 18000 21 4 mA H Runs for 1month 1 30 21 4 642 mA H during the Schedule Days Second calculate the Energy mA H consumed During the rest of the Schedule Days Keeping Approximate Time consumes 0 110 mA Note that Requiring every 8 days is negligible for our case Night Latch Daily energy 24 0 110 2 64 mA H is the Daily average Runs for 11 months 11 30 2 64 871 mA H during the other Days Third calculate the Average Daily Energy mA H consumed in one year Average 642 871 365 4 14 mA H Daily Average for the year Finally how many days will the battery last for this example application Using the 2 D c
42. lt 12 1 All but Shut Down 1 hour delay going from GPS to APX 50 GPS Position Data Codes Bit Value OPM Mode Description 13 0 All Position data is not used Default 13 1 All Position data is used if available for time error correction d View amp Enter Screen By pressing on the buttons labeled View amp Enter and Enter on the keypad the screen shown below will appear VE At the present time this screen is reserved for possible future enhancements and currently does not display any data 51
43. mentioned above in Section I 1 the control system of the Cronos unit relies on an internal clock to run programmed current interruption applications Obviously as discussed above the more accurate the clock time the better particularly with regard to multiple unit applications However there is a trade off between clock accuracy and battery power consumption The Cronos unit can be programmed to operate in two different time modes clock modes namely satellite time and approximate APX time with satellite time being automatically selected during periods of current interruption cycling periods The higher power consumption mode see Section II 3 and Appendix 1 is the satellite time mode which is also the most accurate time mode The APX time mode consumes less power but is a less accurate time mode Our basic philosophy with regard to the operational time modes is that during non critical time periods ie non cycling time periods it is best to conserve battery power at the expense of clock accuracy by operating the clock in the APX time mode Conversely during critical cycling periods it is a requirement to have highly precise clock times and so the satellite time mode is automatically employed during cycling periods at the expense of battery power consumption To conserve battery power during periods when the clock is operating in the satellite time mode rather than continuously tracking the GPS signal the signal is
44. meter Note Since you may have a pipeline that crosses two or more time zones and you may be interrupting rectifiers on the pipeline that are located in different time zones it is imperative that you select the same Local Offset parameter for all of the current interrupters involved regardless of the actual local time at the physical location of each rectifier In other words you need to settle on a particular Local Offset value for all of the current interrupters involved in your application Since you will be selecting cycle start and stop times on this Application Settings window by entering local times see below it is important to be aware of the Local Offset value that you have selected and its meaning 11 The Cronos clock uses Universal Time UTC which is the same as Greenwich Mean Time GMT and when you enter a local time at which to start cycling for example start current interruption the Cronos unit will take the entered local time and subtract the value of the Local Offset that you have selected to arrive at the UTC time at which to start cycling For example if you are operating in the Eastern Standard Time Zone of the U S and you select a Local Offset value of minus 4 4 during daylight savings time summertime the Cronos unit will translate an entered local time for example a start cycling time of 8 00AM 8 o clock in the morning to a UTC t
45. mploy previously saved GPS position data in the No mode The Yes mode option is a special case refinement option 22 For instance if the Cronos unit is to be operated in an urban area amongst tall buildings it is possible that the GPS signal will take an indirect route to the Cronos unit ie the signal will be reflected perhaps multiple times off of buildings before reaching the Cronos unit In this situation you might select the Yes option as a refinement In this case the Cronos unit will use GPS position data either currently obtained or previously saved data to generate a time error correction However in this case you will have to perform a system reset at the current location if the unit was previously used at another location and GPS position data for that location is saved in the unit s memory since this saved position data will not be appropriate for the current location Note If the Cronos unit does not have a view of at least 5 satellites in its current position and you have selected the Yes option the unit will employ the previously saved position data to generate a time error correction assuming that position data was indeed saved previously If there is no previously saved position data in the unit s memory the unit will function as if it were in the normal No mode which does not use position data In order to take full advantage of the Yes mode and to avoid the
46. n the appropriate button on the keypad This will enter the new operating mode however as can be seen by pressing on the VIEW ONLY button all of the other settings will remain unchanged from your presently downloaded settings such as the Night Latch settings the Interruption Cycle settings etc When appropriate some settings will be overridden when you select a different Operating Mode For example if you originally downloaded a Weekly cycling setting with certain Night Latch settings and you switch to a Continuous cycling operating mode via the keypad the unit will override the Night Latch settings since in the new mode the interruption cycle has to run continuously 24 hours a day There are two Operating Mode related settings that you can change via the keypad Firstly if you are in the Delay for x number of days then start operating mode you can change the value of x That is you can change the number of days you wish to delay the start of the cycling period To do so you would press on the Up or Down button on the Main Screen associated with the Delay mode in order to select a number from 1 through 9 ie you can elect to delay the start of current interruption by 1 through 9 days How to Change the Interruption Cycle Number You can change the Interruption Cycle Number by pressing on the button labeled SEL CYC The LCD screen will
47. ng the critical time periods of an application In addition the Cronos unit does not require an external power supply and can run applications for years at a time using an internal battery power source This is possible due to the advanced design of the Cronos unit which results in extremely low power consumption even when the unit is operating in the satellite time mode see Appendix 1 for details on power consumption The MCM Cronos Unit is available in two configurations the 40 amp 40A model and the 100 amp 100A model The 40A model can accommodate current levels up to 40 amps while the 100A model can handle up to 100 amps of current In addition both configurations can operate with up to 170 Volts DC either polarity or up to 120 Volts AC across the terminals The primary difference between the two configurations is the method of dissipating the heat that is generated as rectifier current flows through the relay As current levels increase a more extensive heat sinking arrangement has to be employed As can be seen from the illustration shown below the relay is integral with the control system in the case of the 40A unit both are housed in the same box while in the case of the 100A unit the relay and the control system are housed in separate boxes In both cases the relay design is essentially the same an array of solid state enhancement mode MOSFET switches however the relay is mounted separately from the control sy
48. on This process will download your settings to the first Cronos unit You would repeat this process if you had multiple Cronos units to program The LCD screen will show the NDAT code for New Data in the top right hand corner of the screen while data are being downloaded and for a period of 6 seconds after the last byte of data has been received Note You can also use your PC or laptop to perform the above process in reverse That is you can upload the programmed settings from a Cronos unit to your PC or laptop by clicking on the Get Settings from Cronos button on the Configuration Application Settings window You will be able to view the settings on the two windows that we ve discussed above This is a considerably more convenient way to view settings than to use the keypad and LCD screen on the Cronos unit itself in which case you have to refer to hex codes to determine the settings see Section III below 25 SECTION III HOW TO USE THE ONBOARD KEYPAD The onboard keypad can be used to perform a number of functions as described in the sub sections presented below TII 1 How to View All Programmed Settings and How to Change Some Settings via the Keypad You can view all of the programmed settings that you downloaded from your PC or laptop to your Cronos unit see Section II above by pressing the button labeled VIEW ONLY on the keypad see the Keypad Layout figure below Once you
49. on the Advanced Settings button on the above window The Advanced Settings window will appear as shown below Si Advanced Settings SEE Synchronization System Time Mode JR Synchronization Synchronize at 00 00 everyday Use UTC Time JR Sync Off C Synchronize at Daily Start Time C Use GPS Time C JR Syne On GPS Reaguistition Parameters Normal Reaquire GPS every 3 Hr v or after 15 A v temperature change Backup Retry after 8 days v when in APX mode or 2hr v when in GPS mode Initial Time mode for Night Latch outside of Schedule 1 AP P GPS Time mode for Night Latch inside of Schedule 1 AP GPS Time mode for Night Latch during Delayed Start IW APX GPS Time mode for Night Latch during Weekly Cycle 1 APX GPS Time mode for Always Closed state IW APX GPS Time mode for Always Open state V APX GPS GPS to APX Delay V Gmin 1 hr Special Position Accuracy Position Lock No Yes Relay Delay LCD Contrast Open To Close Delay ms 2 06 Starting Level 7 v Close To Open Delay ms 3 36 Contrast Range fi a Default Settings Cancel Note It is highly recommended that you at least begin with the default settings provided by MCM since the default settings represent the optimum settings with regard to balancing battery power consumption and clock 16 accuracy The default settings are indicated on the above window If you make changes and decide to return to the default
50. only reacquired periodically for example every 3 hours and during the time intervals between reacquisition attempts corrections are continuously made for any clock drift due to temperature variations Consequently precise time is maintained while the unit is operating in the satellite time mode while consuming an acceptable amount of battery power On the other hand the GPS signal is only reacquired while the clock is operating in the APX approximate time mode every so many days typically every 8 days and temperature compensation is not employed in this time mode Consequently clock accuracy is compromised in the APX time mode however battery power consumption is negligible Hence the APX time mode is recommended for non critical time periods non cycling periods where clock accuracy is not critical III 3 How to Shutdown amp Reset the Cronos Unit and How to Wake Up the LCD Screen There is no power switch on the Cronos unit The unit s internal battery system will always provide any reguired power to maintain the functions demanded by a particular Operating Mode see Section II 2 so long as the battery status is good see section IV The unit will arrive from MCM programmed to be in the Shutdown mode which is one of the unit s Operating Modes The Shutdown mode consumes extremely little battery power and this is the recommended operating mode in which to transport or
51. ow below 5 2 volts The v indicates a relative level v 5 is close to 5 2 volts v 0 is at or below 4 8 volts Battery should be replaced at any level since the fall from 5 to O is usually fast depending on the operation When battery is at or below 4 7 volts the ER01 is indicated instead of BATO The replacement of the Battery should be periodic based on the battery type used the PA Configuration parameters set and based on cycle use never depending on the battery low indicators NDAT Indicates that a Complete New Configuration Data set was just received Conditions that are related to this Indication gt A complete Configuration Data set was received at least once gt After No Configuration bytes were received for least 6 seconds prior to the indication gt While connected to the RS232 gt While continuing to receive Configuration bytes this message lasts for 6 seconds after the last Configuration byte was received SMR The SMR Interface failed Usually means the SMR Relay is Not Connected to the Cronos Box SATs The GPS is currently trying to acquire a new set of values from the Satellites Max power is used Where s is a relative number that indicates the time elapsed since the last successful GPS Acquisition s F means either first time acquiring or last successful acquisition was more than 22 days ago E last successful acquisition was between 11 days and 22 days ago D last successful acqu
52. ption cyclic waveforms by clicking on the pull down list arrow in the box labeled Cronos Cycle and clicking on a number from 1 to 5 You can also enter your own values for the On and the Off times for a particular cycle number in which case you will change the programmed waveform represented by that cycle number The time parameter values can be changed in increments of 0 1 second The 5 pre programmed cyclic waveforms are as follows Cycle 1 0 7sec ON and 0 3sec OFF Cycle 2 0 8sec ON and 0 2sec OFF Cycle 3 1 5sec ON and 0 5sec OFF Cycle 4 4 0sec ON and 1 0sec OFF Cycle 5 10 0sec ON and 2 0sec OFF Night Latch Field As mentioned above the Night Latch represents the sleep state for the Cronos unit If you only need to be interrupting the CP current during working hours for example you can save battery power by allowing the Cronos to go into its sleep mode during the non working hours period You can select the Stop cycling time for example 5 00PM local time and the Start cycling time for example 8 00AM local time by clicking on the up or down arrows in the Stop cycling and Start cycling boxes in the Night Latch field Again the system will actually stop cycling 2 minutes prior to the entered Stop Cycling time in the Night Latch field You also have a choice of whether the relay will be held in the closed state or the open state during
53. re the GPS signal at each new operating site Note When the Cronos unit is in the process of trying to acquire or reacquire the GPS signal the code SAT will appear on the Main LCD screen see Appendix 2 in the top right hand corner and when the attempt has proved successful the SAT code will be replaced with either OK or POK Both codes indicate that satellite clock Cronos clock synchronization has been successfully accomplished The difference between these two codes pertains to the number of satellites that were visible by the Cronos unit during the acquisition process If the OK code is indicated it means that 5 or more satellites were visible whereas if less than 5 satellites were visible the POK code will be indicated 21 The POK code indicates that too few satellites less than 5 were visible by the unit to generate new position data which would mean that the unit would employ previously saved position data if called upon to do so see the discussion below under Use of Current or Previously Saved Position Data Option The option to employ position data is only used in special situations as discussed below and normally you would not concern yourself with the POKR indication Finally when the Cronos unit has been in the Shutdown mode say to change the batteries see Section TV or because the unit has been in storage for several months the time period to
54. rform as specified Since the Cronos operates by acquiring GPS clock time satellite time and will not operate in the absence of an acquisition an operational Cronos will be self calibrating as the GPS clock time is assumed to always be accurate SECTION II HOW TO PROGRAM THE CRONOS UNIT FOR YOUR APPLICATIONS II 1 Initial Procedures The process of programming your Cronos unit for a particular current interruption application involves the use of your desktop PC or your Laptop computer We will use the term PC in this context to mean either a desktop PC or a Laptop computer The first step is to load the CD that came with your Cronos or the latest version of the software if you ve received an updated version into the CD drive of your PC When your PC has located the contents of the CD double click on the MCM Cronos icon which will open up the Cronos exe software program file This is the software program that will allow you to setup the conditions of your present rectifier current interruption application The software program also allows you to establish the settings that will control the GPS signal reacguisition schedule during both time modes satellite and APX and also the time mode that will be in effect during each of the non interruption periods of your application II 2 How to Make Application Settings Selections When you open the Cronos software program by double clicking on the M
55. rrelated with the Operating Mode they represent as indicated below see Section II for a discussion on the Operating Modes of the Cronos unit Relay always open rectifier off OPEN Relay always closed rectifier on CLOSE Delay for x number of days then start RUN DEL Weekly cycling RUN WEEK Scheduled start and stop time RUN CALEN Continuous cycling RUN CYCLE In addition to displaying the time local time which will be the UTC time plus your Local Offset and date the Main Screen will also show a variety of other data as indicated below 42 Main Screen LCD s top left shows OPEN CLOSE RUN or SD MMMMMM j FSWSUSTAT 02 306 20030618 MMMMMM Current Switch Operating Mode Options OPEN CLOSE RUN WK RUN CY RUN CA RUN DE SD Shut Down jr JR Sync Indicator Options JR blank SWS Switch Status Options OP CL CYclc 1 2 3 4 5 0P CLA d 1 2 3 4 5 6 7 8 9 c cycle number and d number of delay days This reflects the State of the Switch as it is commanded by the System not necessarily the actual Switch state in case of a failure or when using SMR modules in other that the standard configurations u Upload Indicator Options u blank STAT Status Options in priority order TSMR SMR reports Module has detected an Over Temperature condition it will cancel SMR operations ERee Error Message where ee Error Number See the Error Number List section below BATv Indicates when battery is L
56. settings you can click on the Default Settings button on the above window Synchronization Field You can select to synchronize the leading edge of the current waveform at 00 00 UTC time everyday or at your selected daily start time ie the time you selected to begin current interruption each day see Section II 2 As indicated above the default setting is 00 00 UTC Time System Time Mode Field It is recommended that you select the system s time mode to be UTC time Universal Time You can also select GPS time which differs from UTC time by a few seconds Once you make your choice you should leave this selection as a permanent setting JR Synchronization Field As discussed in Section III 2 it is possible to time synchronize MCM JR Current Interrupters non GPS units using a Cronos unit It is critical however that if two or more Cronos units are being used to synchronize a number of JR units that each of the Cronos units involved be operating in the same system time mode see above Since this clock synchronization process can be performed using a button on the keypad it is recommended that you select the default option here namely the JR Sync Off option When the JP Sync On option is selected the Cronos unit will try to acguire the GPS signal and maintain satellite time which as discussed below consumes battery power GPS Reacquisition Parameters As discussed in S
57. stem in the case of the 100A model since the relay reguires a more elaborate heat sink for more efficient dissipation of heat in the case of the higher current loads As can be seen from the above figure the 40A unit connects directly to a rectifier whereas in the case of the 100A unit the relay box connects to the rectifier and the control box connects to the relay via a control signal cable The control signal cable which can be a few feet to several hundred feet in length depending on the circumstances of the application is connected to the control box by means of a terminal on the front panel labeled SMR Interface Cable 100A unit only The SMR term stands for Solid State MOSFET Relay As mentioned above one of the attractive features of the MCM Cronos unit is that it does not require any external power source The unit runs on battery power alone and the batteries are housed inside of the control box both models As discussed in Section II 3 the lifetime of the battery system in the Cronos unit depends on the operating mode and especially on the GPS reacquisition parameters and the clock time modes that are in effect during cycling and non cycling periods Please see Section IV for a discussion on the important topic of battery life The operational clock modes which have a major impact on battery life are introduced below in Section I 2 1 2 The Two Operational Clock Modes of the Cronos Unit As
58. t are slightly in advance of the times programmed for the Off to On and the ON to Off current interruption waveform transitions This is because it takes the switches MOSFET switches in our case a finite time to respond and stabilize in their new state at each transition The Relay Delays required in the case of our MCM relay are very short 2 06ms and 3 36ms compared to the delays that would be required for mercury switches approx 80ms for example The plus signs associated with the delay values shown on the Advanced Settings window indicate that power will be applied to the relay in advance of the programmed Off to On and On to Off transition times by the specified amounts of time namely 2 06ms and 3 36ms respectively We also provide the option to enter a negative delay value An example of where you might enter a negative delay value is where a Cronos unit with an MCM relay a MOSFET based relay might be operating on the same line as another type of current interrupter with let s say a mercury switch relay If these two units are clock synchronized we can compensate for the mercury switch relay s 80ms response time by selecting a 80ms relay delay setting for the Cronos unit actually a 78ms relay delay since the MOSFET based relay has a 2ms response time of its own In this case the two current interrupters would switch the current at exactly the same time which is the ideal case scen
59. t interruption each day of your programmed schedule at the times you enter in the Night Latch field in the boxes labeled Start cycling and Stop cycling respectively Also as with the Weekly cycling mode you can elect to skip certain days of the week by placing a tick by clicking in the appropriate box beside your selected skip days in the field labeled Disable Interruption On Note The system will actually stop cycling 2 minutes prior to the entered Stop Cycling time in the Night Latch field So if you are running a short term test of the Night Latch feature for example you would need to be cycling for some time plus 2 minutes in order to observe the Night Latch operation Again as was the case for the delay period mentioned above the Cronos unit will be in its Night Latch sleep mode for times outside of the Schedule ie before the Schedule begins and after the Schedule is finished and the relay is typically held in the closed position so that the rectifier current will always be ON outside of the Schedule period in order to keep the pipeline cathodically protected Again you would select the Closed rectifier on option in the Night Latch field if this is the desired case By selecting the Continuous cycling mode you will be electing to interrupt the rectifier current according to the cycle parameters that you select in the
60. the settings data from the mother unit being duplicated on the second Cronos unit A successful copy process will be indicated by the code NDAT for new data appearing in the top right hand corner of the LCD main screen on the second unit The NDAT code will disappear 6 seconds after the last byte of data has been received by the second unit TII 3 How to Clock Sync an MCM JR Current Interrupter using a Cronos Unit It is possible to time synchronize a Cronos unit and a JR Current Interrupter By doing so a JR unit s clock time can be synchronized with the precise satellite time available on the Cronos unit First connect the communications cable between the terminal labeled JR Sync Port on the Cronos unit and the terminal labeled Sync Port on the JR unit Next press on the button labeled JR SYNC Req on the keypad of the Cronos unit This process will cause the Cronos unit to acquire satellite time and to transfer this precise time to the JR unit Alternatively if a Cronos unit is running in the satellite time mode say during a current interruption period you can simply connect a JR unit to the Cronos unit as described above press on the JR SYNC Req button on the keypad and the clocks will become synchronized 31 SECTION IV HOW TO CHANGE THE BATTERIES IN THE CRONOS UNIT As discussed in Section II 3 the lifetime of the main battery system in the Cronos unit depends
61. times from the keypad you can only do this from your PC or laptop as described in Section TI The Select Cycle screen will display a variety of data as indicated below Select Cycle Number Screen LCD s top left shows CY Cl Cus 80 86 g SATO OP 80 28 CYc Currently selected Interruption Cycle Number c 1 in this example May change from 1 to 5 CL s Close time for this cycle in seconds Resolution 0 1 seconds 0 8 seconds in the example OP s Open time for this cycle in seconds Resolution 0 1 seconds 0 2 seconds in the example SATs Relative elapsed time since the last successful acquisition occurred On this screen this is displayed for viewing only and regardless of the acquisition status s 0 indicates less than 1 hour in the example See details under STAT in the Main Screen description above 46 c View Only Screens As discussed in Section III 1 you can view all of the application settings that you downloaded from your PC or laptop to your Cronos unit by pressing the button labeled VIEW ONLY on the keypad Once you are in the view mode you can step through various LCD screens which reveal various data concerning your present Operating Mode by pressing the Up and Down buttons The following are the screens that can be viewed by pressing the Up and Down buttons while in the View Only status View Only screens LCD s top left shows V
62. to store the unit long term Note Since the relay will be in the OPEN state while the unit is in the shutdown mode the Cronos unit should not be left connected to a rectifier while in this mode as CP current will not be able to flow through the relay Very little battery power is consumed in the Shutdown mode since essentially all that is being powered is the internal clock and there is no GPS signal acquisition in this operating mode It should be noted that in all of the other Operating Modes that are discussed in Section II 2 the GPS receiver will power up and try to reacquire the GPS signal every so often based on the programmed settings for the GPS Reacquisition Parameters see Section II 3 This of course would represent a needless drain on the battery if the unit were trying to reacquire the GPS signal while being transported inside a vehicle or while being stored inside a building The unit can conveniently be transferred to the Shutdown mode from any of the other Operating Modes by pressing down on the button on the front panel labeled Single Push Button for between 10 and 15 seconds At this point the code SD will appear on the main LCD screen see Appendix 2 in the top left hand corner and you can release the push button When the shutdown process is complete which will take 1 to 2 minutes the LCD screen will go blank In the Shutdown mode no power is supplied to the
63. uld not be stored below 30 Celsius or operated below 20 Celsius The rest of the unit can operate continuously at 40 Celsius and for short periods of time at even lower temperatures Recommendations If a Cronos unit is expected to operate below 20 Celsius for long periods of time the LCD should be removed and the Keypad LCD should be monitored remotely as described in Section III 1 Consult MCM as to the removal of the LCD Display If unit does not clear this error after Resetting the System and operating at higher temperatures for at least 3 minutes return the unit to MCM for repair ee 05 Data error Unit may have received the wrong set of values to compute the cycle times etc Also any result or internal computed value in Cronos M2 CPU outside the expected range could use this error number regardless of the data source internal or external Solution Resetting the System should clear this error message assuming the unit is no longer subjected to any wrong data values if it was the case of the wrong Configuration data User should check the data loaded to the system Note The System checks some but not all data It is always the users responsibly to provide the right data in the system ee 50 Error reading the internal Temperature sensor Should never occur Solution Send unit to MCM ee 51 Error reading the supply Battery Voltage Should never occur Solution Send unit to MCM ee 52 Error in accessing the perm
64. under which the Cronos unit can exist operating conditions such as relay in the open or closed positions while operating in either APX time or Satellite SAT time or when the unit is acquiring the GPS signal We then applied these data to 3 examples in which we selected particular application settings For each example application we calculated the amount of energy power x elapsed time that would be consumed by the unit while existing in each of the various states operating conditions appropriate to each application over the course of a day The elapsed time is the time the unit spends in a particular state condition We then calculated the percentage of energy used Used during each state condition by dividing the calculated energy in each case power x elapsed time by the total energy available from the battery system and multiplying by a hundred Based on the above outlined calculations we were able to project a battery system lifetime for each of the 3 example applications Note We determined projected lifetimes for both the main battery system 2 D Cell batteries and for the emergency battery running each of the 3 example applications Power Consumption Data Our data for power consumed versus state operating condition are shown below for both the main battery system the mA 6 8V data and the emergency battery the mA 8V data 36 Operating Power Power Comments Condition mA

USER`S MANUAL - The M.C. Miller Company

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