The Acoustic Level Detection Module (ALDM) for Two and Three
Contents
1. Figure 22 A conceptual three phase separator that requires a VAC constant The default value is 64 61 ml This value can be set and is reported as 6461 by the Data Link card the last two digits are always assumed to be right of the decimal point 34 42 Acoustic Level Detection Module ALDM User s Manual For example if anew VAC value is determined to be 50 33 ml you would send the command c5033 to the Data Link card All other commands not listed in the graphic above are forwarded to the individual bores and each response is forwarded back The response from Bore A is preceded by an A and the response from Bore B preceded by a B The Host Data LED illuminates Data Link card receives a command from a host The LED is turned off when the entire transaction is completed The Bore A Data LED blinks when the processor is waiting for a response from Bore A and the Bore B LED blinks when the processor is waiting for a response from Bore B A problem with a bore s data stream can result in a non responsive Data Link card and one of the Data LED s remaining continuously lit 35 42 Acoustic Level Detection Module ALDM User s Manual 6 2 Description of Electronic Functions ALDM measurements are carried out under the control of one or more embedded computers in the electronics console The acquisition process starts when the control system initiates an ultrasonic2. 13 42 Acoustic Level Detection Module ALDM User s Manual 4 5 Transducer Assembly The ALDM comes supplied with a specially designed ultrasonic transducer assembly Transducer Assembly Components 2 Phase Separator Systems Qty Description Ultrasonic Reference Target Reference Target Stand Ultrasonic Transducer Assembly 1 Spare Ipkg 119 Viton O rings BNC Connector Block Transducer Assembly Components 3 Phase Separator Systems Description Ultrasonic Reference Target Reference Target Stand Ultrasonic Transducer Assembly 1 Spare Ipkg 119 Viton O rings BNC Connector Block i The Ultrasonic Transducer Assembly may arrive wrapped in black plastic tape The tape ensures that the assembly remains intact during shipment The tape also provides minimal strain relief for the signal wires The signal wires are very fragile and can be easily broken Remove the shipping tape before inserting the assembly into an appropriately sized holder Be careful handling the transducer when the shipping tape is removed The transducer assembly will require the attachment of the two signal wires for operation These wires must be soldered with the supplied high temperature solder or a similar solder rated for your operating temperatures The black wire from the transducer should be connected to the shield connection of the BNC connector The other wire may vary in color red white etc and should be co
3. STATS OK26839 21278167411129 212781674 bytes 1 2 3 4 5 6 7 8 olio ti 12 13 14 15 16 17 18 19 20 2122 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 SEDREEOREBEEEE PERE Eee Dee eee HOLE Light Fluid delta Light Heavy Fluid delta Heavy Volume Fluid Volume Fluid Volume NNN NN NNN NN NNN NN ml ml ml ALDM Serial Output Error Code Where Anything other than STATS OK indicates a software or hardware problem the absolute volume of the light fluid running delta reset to zero if a r is received The speed of the heavy fluid in meters second the absolute volume of the heavy fluid running delta reset to zero if a r is received Speed Heavy Fluid The speed of the heavy fluid in meters second repeated Request Data Distribute this string to all embedded ASCII ENQ 05h followed by ASCII character CR ODh ORa CPU s Wait for responses Modify followed by ASCII character CR ODh returned Absolute Volumes as necessary Reply to Host with modified values Volume Reset Send same command R or r out to all R 52h or ASCII r 72h followed by ASCII character CR ODh embedded CPU s No response expected Reset internal delta volume values to 0 Decimal points are implied and not sent Leading zeros or spaces are present when number is less than full scale Relative Volume uses ASCII 2Bh and ASCII 2Dh to indicate whether volum
4. This is the ultrasonic transducer connection for Bore B Connect the transducer using the supplied high temperature coaxial cable Diagnostic A Diagnostic B Three Phase Separator These are the diagnostic serial ports for the Bore A and B CPU s Protocol settings are 9600 baud 8 n 1 No connection is required for normal use Video A Video B Three Phase Separator Video output for each bore These outputs may be connected to an external KVM switch to allow the use of one video monitor Serial Port Data acquisition and control port This port is commonly connected to Quizix control systems It may also be connected to any computer using a serial terminal program See section 4 8 EIA RS 232C Communication Port for configuration information and available commands Keyboard A Keyboard B Three Phase Separator Connect an external keyboard adjust the configuration settings These ports may be connected to an external KVM switch to allow the use of only one keyboard Mouse A Mouse B Three Phase Separator These connectors currently have no function CPU Reset A CPU Reset B Three Phase Separator When pushed these buttons reset the corresponding embedded CPU Effectively restarts the system without disconnection the power Each bore ha an independent CPU Reset button 28 42 Acoustic Level Detection Module ALDM User s Manual 6 Principle of Operation This section contains functional descriptions keyed
5. e The proper fusing for the electronics is selected by adjusting the Power Entry Module located on the back of the electronics console 7 42 Acoustic Level Detection Module ALDM User s Manual e Becertain to use 250V fuses in all locations Fuse Installation Instructions 1 DN ee IN T Remove power cord Pry door open at socket Lift and swing door into socket Lift fuse holder out of housing Install one 1 AG fuse or two 2 metric fuses Replace fuse holder into housing Swing and snap door back in place Install fuses on one side only Do not install both AG and metric fuses at the same time Figure 1 Removing the fuse holder 8 42 Acoustic Level Detection Module ALDM User s Manual 1 North America 3 Amp 250V 3AG 4x 1 Time Delay Europe 3 Amp 250V 5mm x 20mm Time Delay 9 42 Acoustic Level Detection Module ALDM User s Manual 4 4 Basic Cable Connections First familiarize yourself with the ALDM components and some typical separator pressure vessels UIO TU Bore B OTe O O Dota Link Status o O o oO fe fa olo olo olo olo olo Figure 4 Electronics console front view three phase separator version 3 Phase Acoustic Separator oO Na e 5 a it Tsee liyina a ZEJ s New England Research Inc 3
6. g Power Input C10 240 VAC 0 60 Hz EBRI 0 Figure 5 Electronics console rear view three phase separator version Port status indicator LEDs Manual port selection button Console VGA ports 2nd computer 1st computer VGA port VGA port 2 Port 2nd computer PS 2 1st computer PS 2 Console PS 2 mouse keyboard ports mouse keyboard ports mouse keyboard ports Figure 6 KVM connections 10 42 Acoustic Level Detection Module ALDM User s Manual Vent Sin Light Fluid Output Separation Bore Measurement Bore SSIS SSS Reference Target Ultrasonic Tranducer aes Ua C Heavy Fluid Output Ultrasonic Transducer Connection Inlet Mixed Fluids Figure 7 Typical two phase separator vessel 11 42 Acoustic Level Detection Module ALDM User s Manual p Light Fluid Light Fluid Hapa gt q Middle Fluid I G7 OOD Heavy Fluid Measurement Zone i 7 Measurement Zone L4 y Bore B Ultrasonic Transducer Connection Mixed Fluid Input Bore A Ult ic T d w Heavy Fi pene Output Figure 8 A hybrid three phase separ
7. pulse transmitted from the transducer The ultrasonic energy is transmitted into the fluid in the vessel This energy wave first encounters the reference target that is placed a known distance away from the transducer face Some of the transmitted energy is then reflected back to the ultrasonic transducer This reflection from the target is then received by an ultrasonic amplifier and routed to the data acquisition subsystem and stored in memory However most of the ultrasonic energy passes by the reference target and continues past When a fluid interface is reached again some of the energy is reflected back toward the ultrasonic transducer This reflected signal is also acquired and saved to be processed The embedded computer then processes this information automatically matching the acquired waveforms with a stored library of reference waveforms From this match an accurate and stable pick time can be calculated The system automatically calibrates out any pressure and temperature effects on the fluid by using the information from the reference target waveform The speed of the heavy fluid is then calculated Next the arrival of the fluid interface is processed and along with the stored vessel geometry information the fluid volumes can be calculated This information is then displayed on the video output and is made available to the digital serial link if present This entire process is automatic and does not require any user inte
8. E 28 Keyboard A Keyboard B Three Phase Separator sssesseseessseesesreessreeresesreeesresreseeersserrrsresrreresee 28 Mouse A Mouse B Three Phase Separator cesessceceseceesceceseceesceceseeeeneeceeesenaeceeeeeneeceseeeeneeees 28 CPU Reset A CPU Reset B Three Phase Separator 000 0 ceececsseceeneeceeeceeeeeceeeeeneecsaeeeeneeceaeeseneers 28 Principle of Operation sivcvciscsssssssovscscavasssisnvnnssnassavassnenancssnesavstehestnssssensncsenessavesegensbes 29 2 42 Acoustic Level Detection Module ALDM User s Manual 6 1 Three Phase Separators The Data Link Status Panel csssccssssossssssssescsssees 32 6 2 Description of Electronic Functions ccccccssssccssssscsssscsssscsssescssscssessssssessssesesses 36 6 3 Error MICSSA GOS scscecessasc ntcccheaticsscecetcecsctdencebccwscccuccdisivscesecedsccdessusccwersedcadeaseccceerssacacensce 38 7 Ultrasonic TANS AUC Sessccississccescssisscsesdscccesavseccsedescscscavisssonsvscedessascssavssecsssexdsesessetee 40 Serial Commands cvirscsiccssiiesssciisdeavassscianessasinutiscedionnsetenresseniavevartaeussarasivesaenecweniaesese 41 Two Phase and Three Phase Command cccccccccecsssscecececeessssececececsessececcesceenssneceseceesessnssaeeeeeens 41 O OO a eo ee Fe EE EEE EER RRS 41 RAOT E e AE AERE EE R E E EEE A E A EREA A AO E AE E 41 Additional Three Phase Separator Commands csscssccssecseesecseeeeceseeecsaeceeesecaeesecnaeeeceaecaee
9. Installation Guide amp User Manual The Acoustic Level Detection Module ALDM for Two and Three Phase Separators Part Numbers NERAS 2000 ELEC NERAS 3000 ELEC Serial Numbers NERAS10XX Rev 1041_2007 02 27 New ENGLAND RESEARCH Other product and company names listed are trademarks or trade names of their respective companies Acoustic Level Detection Module ALDM User s Manual Table of Contents Tableof Contents ni eaea biadoea spies ag voto os ONG HIER ME RENEA 2 Table of Figures icsii is siacuscicasscaadesswciadoavestsueka vognghsvunnssondhtssansavskhanadavebeneusncstiesavebeseseisesn 4 General Information S svsvusssswcessasiscsavacyesesssetnaxsishvsdenasseuedevianedessbesnsusss eia aa sais 5 3 1 Tntroduchom so ciisiecc debs sceccssnsvesinsessteisbescecsesssccsesbeseecsnsssocedeeeduedeesssonsesoudusseess socebesesussseses 5 3 2 S DECIFICALIONS ceccectaececesssvorsvenaccecedsssennectuaceceeesoedectexesd sugseetecossuess sepssesuecebucsecegsdeduaesdoasededse 5 3 3 ACCESSOLIES Supplied vise ccsssissnconsecdcosses sesso ssoesesssSioedesdecdsasdncdoscas seonce suassdesaess ctesessesssceeses 6 Installation Interfacing and Safety ssccccssccssrrcssssscssssccsssccsssccessscesssscesesscsessscess 7 4 1 Initial Inspection cisscascsscscesiescssetesesssssesctsvescsecnsosboonsonsees sestsescSssesceonsevsscesoosesesestsessesonses 7 4 2 SALCLY ATEA E ER E E E E S A 7 4 3 Power Selection aaaea AEK AREENA KATARE es doeseunccestseusdete
10. Link Card Returns the value of the Volume Adjustment Constant If the command is followed by a number set the constant to the new value and save to flash memory Return Version Number i V or v followed by ASCII character CR ODh Returns the current firmware version code Commands with are NER diagnostic commands Not required for Quizix compatibility C or c lt optional value gt followed by ASCII character CR ODh Decimal points are implied and not sent Leading zeros or spaces are present when number is less than full scale Relative Volume uses ASCII 2Bh and ASCII 2Dh to indicate whether volumes are higher or lower than when last reset Figure 11 Three Phase Separator Serial Protocol Example 24 42 Acoustic Level Detection Module ALDM User s Manual 4 9 Integration with Quizix PumpWorks The ALDM for two and three phase separators from New England Research Inc are fully compatible with the current PumpWorks software release from Quizix V 5 35 B5 Quizix supplies pumps that are commonly used in separator systems Please note that New England Research Inc makes every effort to ensure that our Acoustic Level Detection Modules will function seamlessly with PumpWorks However we cannot guarantee this functionality for different versions of PumpWorks or hardware changes that are beyond our control Quizix Incorporated 4616 Roseville Road Suite 108 No
11. M Output Three Phase ALDM Output Error Codes Error Codes Bytes 9 13 Absolute Volume of the Light Fluid Absolute Volume Upper Phase a Bore B Light Fluid Relative Volume of the Light Fluid Relative Volume of the Light Fluid Bytes 20 23 Heavy fluid velocity Fluid Velocity Bore B Middle mea meters second Fluid Byte 24 28 Absolute Volume of the Heavy Absolute Volume of the Heavy pee Fluid Fluid Lower Phase Bore A Relative Volume of the Heavy Relative Volume of the Heavy Fluid Fluid Heavy fluid velocity Fluid Velocity Bore A Heavy meters second Fluid Carriage Return ODh Carriage Return ODh Table 4 RS 232 Data Format e Absolute volume 5 characters NNN NN in ml e Relative volume 6 characters NNN NN in ml e Sound velocity 4 characters NNNN in m s All characters are numeric ASCII 30h to 39h Leading zeros are used when number is less than full scale Relative volumes use ASCII 2Bh and ASCII 2Dh to indicate whether the volumes are higher or lower than when last reset Decimal points are implied and not sent 22 42 Acoustic Level Detection Module ALDM User s Manual A response to a status query is listed blow for both two and three phase systems Please note that the list may include commands that are not compatible with earlier versions of the ALDM or other manufacturer s control systems ALDM Response to a Host Computer Command The Command lt Carriage Return gt
12. STATS OK26839 21278167411129 212781674 bytes a 2 a 5 7 o 5 a ral 020 a fa 2a 25 oe a ope se SED0 5800 2oBo Sees Poe eee ee Light Fluid detta Light SPEC4 MEAWE seita Heavy Speed Volume Fluid Volume Fluid Volume ree Data Link Output Error Code i Fluid NNN NN NNN NN Ninn NNN NN mi mi s im m s Where the OR of error codes of Bore A B volume reported from Bore B running delta reset to zero if a r is received Middle fluid speed as reported from Bore B Heavy Fluid Volume from Bore A Volume Adjustment Constant running delta reset to zero if a r is received Speed Heavy Fluid Heavy fluid speed as reported from Bore A Command from Host Action by the Data Link Card Rogues Daja Distribute this string to all embedded ASCII ENQ 05h followed by ASCII character CR 0Dh OR a CPU s Wait for responses Modify followed by ASCII character CR 0Dh returned Absolute Volumes as necessary Reply to Host with modified values nS Henan Send same command R or r out to all R 52h or ASCII r 72h followed by ASCII character CR 0Dh embedded CPU s No response expected Reset internal delta volume values to 0 Config Data Link Card Returns the value of the Volume Adjustment Constant If the command is followed by a number set the constant to the new value and save to flash memory Return Version Number j V or v foll
13. a packet should start with STATUS OK message and a Status OK indication should appear on the video output Table 5 is a complete list of the error codes and the necessary corrective actions for Two Phase Separators DISPLAY TEXT RS 232 CODE Cause action STATUS OK STATS OK System is operating normally ERRI SOUND VEL ERRORI Oil water interface is too close to the COUNT LOW transducer Add water Noise level exceeds threshold when the detector is enabled causing erroneous reference and echo detection ERR2 SOUND VEL ERROR2 Too weak reference signal Reference COUNT HIGH target is out of adjustment ERR3 WAT OIL INT ERROR3 The oil water interface is too low Add COUNT LOW water ERR4 WAT OIL INT ERROR4 The oil water interface is above upper COUNT HIGH limit Drain water Table 5 Two Phase Separator Error Codes In addition to the errors codes listed above Table 6 is a list of the additional error codes and the necessary corrective actions for Three Phase Separators DISPLAY TEXT RS 232 CODE STATUS OK ERRORO ERROR8 ERROR8 Cause action This bore is operating normally Communication timeout There is a problem with the embedded communication bus Contact NER ERROR9 ERROR9 Garbled data received Try removing any sources of electrical interference from the proximity of the ALDM system Contact NER Table 6 Three Phase Separator Error Codes 38 42 Acoustic Level Detection Mod
14. ator vessel 12 42 Acoustic Level Detection Module ALDM User s Manual Cables supplied with this system e A 2 VGA Video cables for use with the KVM switch e B 2 PS2 Keyboard cables for use with the KVM switch e C 2 PS2 Mouse cables not required for operation for use with the KVM switch e D 2 Teflon coaxial separator signal cables e E 1 Electronics console power cord e F 1 9 pin serial cross over cable Connections required for standalone operation Electronics Console To Use Cable Type Video A KVM 1 VGA Port A VGA video cable Video B KVM 2 VGA Port A VGA video cable Transducer Bore A Separator 1 Ultrasonic D Teflon coaxial cable Transducer Pressure Vessel Transducer Bore B Separator 2 Ultrasonic D Teflon coaxial cable Transducer Pressure Vessel AC Power Source Electronics Console E Power cord Console VGA To Video Monitor VGA Video Monitor Cable Connections required for configuration and diagnostics only Electronics Console To Use Cable Type Keyboard A KVM 1 Keyboard Port B PS2 Keyboard Cable Keyboard B KVM 2 Keyboard Port B PS2 Keyboard Cable Diagnostics A or B Host Computer F Cross Over Cable Console Keyboard To Keyboard Attached Keyboard Cable Connections required for remote data transfer amp control Electronics Console Use Cable Type Serial Port Host Computer or Quizix F Cross Over Cable Computer
15. cluded Block diagrams theory of operation and separator disassembling assembling information are provided for use in maintaining the instrument as well as a spare parts list 3 2 Specifications This section of the manual contains performance specifications for the ALDM instrument It also lists the accessories supplied and includes instrument and manual identification information Table 1 Transducer Specifications and Table 2 Electronics Specifications provides a complete list of the ALDM critical specifications me Ree ane Maximum change of oil volume 99 ml ml Typical volume resolution 25 4 0 08 mm bores water paraffin Hysteresis 0 3 ml Transducer construction PZT 5A plastics viton and epoxy Transducer wetted parts Plastics viton o ring Transducer resonance frequency MHz Typical A2D Sample Period User le 7 Second adjustable 2 5e 7 to 2 5e 8 Maximum trace length 125 000 Required Vertical Positioning 2 5 deg from true vertical PF Table 1 Transducer Specifications 5 42 Acoustic Level Detection Module ALDM User s Manual a er a PumpWorks compatible pee re sees a S Stop bit s 1 stop bit Hi fF Mains supply 100 120 220 240 Auto switching VAC Table 2 Electronics Specifications Due to fluid surface mechanics i e reversal of the meniscus surface when changing from rising to falling liquid levels or vice versa a hysteresis effect occurs in the measurements To minimize thi
16. cssscsssscsssessssccsssesssssesssssees 25 The ALDM Console scccccsssciscsssssccssvscccosatsscesssesacdnccessssvncssesenedtigesesstsic ssateesesasssiesssstss 27 5 1 Front Panel Description cssscssssccssssscssscssssscssssccssscssssssssssssssssscsssssssesssssescsssees 27 POWer ON INGIC ALORS 15 scs03 csc 2s cise saa rca tesa chen cs ces aia eka aves see es R a AS 27 CPU Bore A and CPU Bore B Three Phase Separator cccceseccsesecesesecseeesesseeesssessessenes 27 Volume Reset Bore A and Volume Reset Bore B Three Phase Separator esseeeeeeeseeeeee 27 Host Data Bore A Data and Bore B Data Three Phase Separator ssccesececsseceeeeeneeeees 27 5 2 Rear Panel DeSCription sincecccescsecsssecestencsvoiecesvaceeveocevessesestesveusevsodeescceesoensssunecsseatsosesss 27 POWer Input en e Bosses etiys ct iss thn sen Se a eE EEEE E REEE ES ig E EE OEE EE EE E EE EIEE OEE 28 TEANSAUCEL BOre A a a a a a a ae a a e a a TE a EEE EENE RE 28 Transducer Bore B Three Phase Separator ceceesscesceceseceeseeceseeeenceceeeeeneeceeeseaeeceeeeeeneeceeeeeeneeens 28 Diagnostic A Diagnostic B Three Phase Separator sseseseeesrsseeresessstsreresrersrstsrerrererssesrsrerrerseses 28 Video A Video B Three Phase Separator ccceccesscesseeesceseceseceseeeaecaecneecaeecaeeeeeeseeeeeeereneeeeaeenaes 28 Sera POL ARANT E OEN SE ENE EANA NEE EE A EEEN EEEE E EE E E E EEE EE
17. e 19 Staggered three phase separator 31 42 Acoustic Level Detection Module ALDM User s Manual 6 1 Three Phase Separators The Data Link Status Panel Data Link Status O Dats O ha O erate O O D O Figure 20 Data Link front panel The Data Link feature allows the two data streams from each bore A amp B to be merged and sent out the serial port on the back of the electronics console The Host Data indicator will illuminate when a command from a host computer is pending and waiting for a response The Bore A Data and Bore B Data indicators will illuminate when there is a measurement being acquired from the respective subsystems An indicator that remains lit informs the user that communication with a subsystem could not be established Please check the condition of the communications cable The Data Link card is connected directly to the serial port connector on the back of the ALDM console You may configure and test the operation of the data link by using a general purpose serial terminal program like HyperTerminal which is installed by default on most Windows computers The serial port configuration is described in section 4 8 EIA RS 232C Communication Port on page 20 32 42 Acoustic Level Detection Module ALDM User s Manual Data Link Card Response to a Host Computer Command The Command lt Carriage Return gt
18. e Electronics Console s power switch is in the On position and the unit is receiving AC power CPU Bore A and CPU Bore B Three Phase Separator This red indicator flashes when the embedded CPU is active A program or hardware error is indicated by this LED remaining constantly on or off Volume Reset Bore A and Volume Reset Bore B Three Phase Separator When this red switch is pushed the relative reading of liquid level is set to zero Host Data Bore A Data and Bore B Data Three Phase Separator These panel mounted LED s indicate serial communication activity with an external host 5 2 Rear Panel Description 3 Phose Acoustic Separator Power Input C110 240 VAC 0 60 Hz EBE Figure 16 ALDM Electronics Console Rear Panel 3 Phase 27 42 Acoustic Level Detection Module ALDM User s Manual Power Input Main AC supply connection and fuse location Connect 110 240VAC at 50 60 Hz Maximum current is 4 amps Transducer Bore A This is the ultrasonic transducer connection for Bore A Connect the transducer using the supplied high temperature coaxial cable Transducer Bore B Three Phase Separator
19. e KVM switch allows the embedded CPU s to utilize a single monitor mouse and keyboard without taking up any additional desk space All of the required cables are included Please inspect all of the ALDM parts carefully and read all of the manuals included In addition to this set of instructions there may be other manuals provided which describe the components of the ALDM in greater detail 4 1 Initial Inspection This instrument was carefully inspected both mechanically and electrically before shipment It should be in perfect order upon receipt To confirm this inspect the instrument for damage that may have occurred in transit 4 2 Safety e Ground the instrument To avoid shock hazard the instrument chassis must be connected to an electrical ground The instrument is equipped with a three conductor AC power cable e Do not operate in an explosive atmosphere e Keep away from live circuits e Dangerous voltages are present in this instrument e The ALDM separator is designed to be used with high pressure high temperature equipment Damage to the device under operation or improper assembly may lead to leakage which can cause serious injury to personnel 4 3 Power Selection The instrument can be operated from 110 or 220 Volts AC single phase power supplies according to the fuse setting on rear panel of the ALDM unit e Confirm that the electronics console has the correct fuses installed for the power at your location
20. e accomplished using the following procedure Keep in mind that you can change the configuration settings for only one bore at a time For three phase separators any changes that are applied to Bore A may also have to be applied to Bore B To modify the ALDM configuration file 1 Start with the ALDM electronics turned off 2 Make sure the monitor and keyboard are plugged into the ALDM electronics console or KVM switch 3 Turn the power to the ALDM electronics console to On Press any Kev to Ente tHe Ani yee tnt ailgen Byes ty J seers 4 When a blue screen with the text Press any key to enter the menu appears quickly press any key on the keyboard If you do not press a key within time the ALDM will boot normally If this happens power cycle the electronics console or press the CPU Reset button on the back of the ALDM electronics to try again 16 42 Acoustic Level Detection Module ALDM User s Manual Hed ii H bo UES Wp maintenance linux 2 4 18 3 vesa loop 4 Pail aia wg sa lanr ipiesyy ameu iz Jini o boot the selected OS Cee To edit the ME DOOCIT Say Lo MATEG GHE KEE oe a commandline J By default the embedded linux entry is selected Using the arrow keys select maintenance option then press enter 6 The ALDM will now boot into maintenance mode Eventually a login prompt will appear Type root without quotes and pres
21. edacedecees 7 Fuse Installation Instructions snt ann eien ei a e A EER E E E RRES 8 4 4 Basic Cable Connections e sseseesseceessoceessoceesseceessoceesseceesscceessoceessoceesseceesseceesseceessocee 10 Connections required for standalone operation essessseseseseseesessreeessesrtsesetstrsteressteeesreserseeseeness 13 Connections required for configuration and diagnostics only s sesessseeesssesersseseeserseeeessrseessesees 13 Connections required for remote data transfer amp control sssseesesesssssesesssteeessesestsseeeessrseessesens 13 4 5 Transducer Assembly scedcccsecaccsssseedsessacecesensdsndecesntcssenesssaneysendssssessnsoassosdsssvesssencssences 14 4 6 Turning thesystem OM sacecscsescccsesessec esescessdoessestecesocssesessssonss sonssssnsescsasssossdssasessseass 15 4 7 ALDM Software Configuration fbas ini scsscsssssssscssscsesssesscesceessseessesees 16 To modify the ALDM configuration file eccecceesceesceeeceeeceeeesecesecaeeeneeeseenneeneees 16 ALDM Software Configuration variables cccccesscesscesecesecesecenecececaeeeaeeeseeeeeenessreeeceaeeeaeesaeenaeents 18 Default contents of the fbas ini configuration file 0 eee eeesecseeeeceseeeceseceeesecseesecnaeeecsaecaeeaeeneaes 20 4 8 EIA RS 232C Communication Port cccsscccccssssssccssssscscssssccssssscccesssscecsssssceceses 21 4 9 Integration with Quizix Pump WOrKS ccsscssssccssssc
22. ers when followed by a new line or carriage return as detailed below Each response is terminated by a new line Two Phase and Three Phase Commands or 0x05 The ALDM will return the standard status information and data See Figure 10 Two Phase Separator Serial Protocol Example or Figure 11 Three Phase Separator Serial Protocol Example rorR Send a reset command to the ALDM This will reset the relative volume counters Additional Three Phase Separator Commands corC Set or report the internal volume adjustment constant calibration See Figure 11 Three Phase Separator Serial Protocol Example vor V Return the version number of the data link card firmware 41 42 Acoustic Level Detection Module ALDM User s Manual End of document 42 42
23. es are higher or lower than when last reset Figure 10 Two Phase Separator Serial Protocol Example 23 42 Acoustic Level Detection Module ALDM User s Manual Data Link Card Response to a Host Computer Command The Command lt Carriage Return gt STATS OK26839 21278167411129 212781674 bytes EEEE ea EM WEN ee EE SDD 05800 Boo Seno ooo ee Bee ee NNN NN NNN NN ml ml NNN NN ml Light Fluid delta Light jeni delta Heavy Data Link Output Error Code Volume Fluid Volume zA Nome Fluid Volume NNN NN Where the OR of error codes of Bore A B volume reported from Bore B running delta reset to zero if a r is received Middle fluid speed as reported from Bore B Heavy Fluid Volume from Bore A Volume Adjustment Constant running delta reset to zero if a r is received Speed Heavy Fluid Heavy fluid speed as reported from Bore A Command from Host Action by the Data Link Card Request Data Distribute this string to all embedded ASCII ENQ 05h followed by ASCII character CR 0Dh OR a CPU s Wait for responses Modify followed by ASCII character CR ODh returned Absolute Volumes as necessary Reply to Host with modified values Kmo REGL Send same command R or r out to all R 52h or ASCII r 72h followed by ASCII character CR 0Dh embedded CPU s No response expected Reset internal delta volume values to 0 Config Data
24. hadow from the target will interfere with the acquired signal titlestring User configurable string that is displayed on NER ALDM the NERAS monitor If not specified defaults to Acoustic Separator This string cannot be more than 34 characters long 19 42 Acoustic Level Detection Module ALDM User s Manual Default contents of the fbas ini configuration file stuff you might BUT NEED NOT NECESSARILY change text labels MUST be in double qoutes set titlestring Acoustic Level Detector set heavyname brine set lightname oil bore sizes in inches set borediam 1 00 set borediam2 1 00 stuff that may need field changes but that s really tricky and can break the whole system in hard to detect ways CONSULT THE VENDOR before you change any of these set maxrange 14 00 set minrange 5 00 set cmin 0 8 set cmax 2 0 set dt le 7 STUFF YOU SHOULD NOT N special license T ED TO CHANGE EVER EVER EVER without a SH E SHE HE HE SHE set serialnumber 1027 set default_boxcol hotpink set bgcol azure set plotfont hersheyserif bold set resultfont courier bold set usel2 0 set useenv 1 set agamma 0 01 set etasim 0 1 set amplpwr 2 0 set h2htime 14 88 set refrange 2 00 set refreflead 2e 6 set intreflead 2e 6 set xpixels 1024 set ypixels 768 se
25. nnected to the BNC center pin 14 42 Acoustic Level Detection Module ALDM User s Manual Z Z aA e Measurement Bore not supplied by NER G m a Reference ee ee Target m Target e a Stand Ultrasonic ee ee Transducer Transducer Holder not supplied by NER Transducer _ _ BNC Connection Figure 9 Ultrasonic transducer assembly 4 6 Turning the system On The main system power switch is located on the back of the electronics console Upon activation the separator system starts the boot procedure Progress as well as any error or diagnostic messages will appear on the video output For three phase systems the boot procedures as well as all other functions are independent for both Bore A and Bore B You may need to change the KVM selection to view the desired output Eventually a graphical display will appear that shows the current output of either Bore A or Bore B You can switch the view of the current output to another bore by changing the KVM switch setting 15 42 Acoustic Level Detection Module ALDM User s Manual 4 7 ALDM Software Configuration fbas ini The various software settings used by the ALDM computer are held in a configuration file titled fbas ini If the hardware setup is altered it may become necessary to adjust the settings in the fbas ini file This can b
26. onsole Front Panel Three Phase Separator 27 Figure 16 ALDM Electronics Console Rear Panel 3 Phase 27 Figure 17 A typical two phase separator vessel ssseseeseeeseesessesssesreesetsrerrrsseesseseeesresse 29 Figure 18 A hybrid three phase separator esseeesesseseesessresressessresreeserserereseesseseresresse 30 Figure 19 Staggered three phase separator essesesesssseesessresressessresreesersrereresreseeseresresee 31 Figure 20 Data Link front panel ieena a ae ae 32 Figure 21 Data Link serial protocol esseseeseeeseesesseserssresseseresressessresreesetsresteesresseseeesresse 33 Figure 22 A conceptual three phase separator that requires a VAC constant 34 Fig re 23 ALDM Video Sereen a a A ate A TER ET es 37 4 42 Acoustic Level Detection Module ALDM User s Manual 3 General Information 3 1 Introduction The NER Acoustic Level Detection Module ALDM part number NERAS 2000 ELEC NERAS 3000 ELEC is a precision ultrasonic level monitor The ALDM measures the level of two fluids in a gravity based 2 phase high pressure separator It provides output signals serial ASCII characters proportional to either absolute level or relative to a user selectable set point This manual contains installation and operating instructions for the ALDM used in both 2 Phase and 3 Phase separator configurations Instrument specifications and procedures for verifying proper operation are in
27. owed by ASCII character CR ODh Returns the current firmware version code Commands with are NER diagnostic commands Not required for Quizix compatibility C or c lt optional value gt followed by ASCII character CR ODh Decimal points are implied and not sent Leading zeros or spaces are present when number is less than full scale Relative Volume uses ASCII 2Bh and ASCII 2Dh to indicate whether volumes are higher or lower than when last reset Figure 21 Data Link serial protocol 33 42 Acoustic Level Detection Module ALDM User s Manual The Volume Adjustment Constant see Figure 22 A conceptual three phase separator is a constant value in ml that is subtracted from the Heavy Fluid volume This is required for a staggered 3 Phase vessel setup where the separation and measurement bores for the heavy fluid are not the same length The Volume Adjustment Constant VAC can be calculated by 2 Hei ghtDifference mm x TX BoreRadius mm VAC mi 1000 Light Fluid Output SS a o F Measurement Zone PA Ne an Measurement see Fluid oe m Po tput O Bore B Ultrasonic Transducer Connection Volume Adjustment Constant VAC Heavy Fluid A g i Mixed Fluid Bore A mT Input Ultrasonic Transducer _ __ o Connection
28. reboot command to restart the separator system After the system successfully restarts you can then power down using the main power switch ALDM Software Configuration variables The syntax for values in the fbas ini configuration file is set lt variablename gt lt value gt e One entry per line e All variables are case sensitive e If value is a string with spaces use quotation marks around the value Variables in fbas ini that may be modified Variable Function Typical Value borediam Bore diameter in inches Measurement Bore Actual Bore diameter borediam2 Bore diameter in inches Separation Bore Actual Bore diameter cmax Max allowable Heavy Fluid speed KM s cmin Min allowable Heavy Fluid speed KM s h2htime Head to head transducer time in 10 6 14 88 seconds Separator vessels with unexpected geometries can be accommodated by adjusting the bore diameters as needed to allow the ALDM to report correct volume measurements 18 42 Acoustic Level Detection Module ALDM User s Manual heavyname String label for heavy fluid normal text characters only no square brackets lightname String label for light fluid normal text characters only no square brackets maxrange in inches Bore length minus safety margin Typical value Bore length 1 inch minrange in inches Closest possible acquisition be wary of making this too small the ultrasonic s
29. rth Highlands CA 95660 Www quizix com Quizix product and company names Quizix PumpWorks are trademarks or trade names of Quizix Incorporated The ALDM console may be detected automatically upon starting PumpWorks If this is not the case you can manually configure PumpWorks to recognize and control the two or three phase separator ALDM as shown below l Select Communications Separator Communications gt Separator 3 select Separator 3 even if you are using a two phase separator m Quizix PumpWorks Main Datalog AutoOp Graphing Other Error Log Configure Kecu ons Search for Pumps Search Options Pump Communications Separator 1 Separator 2 Host Mode Communications Separator 3 View Communication Status Update Front Panel Software Update Pump Controller Software NoPumps Active Data Logging OFF Sequencer OFF No Errors Figure 12 PumpWorks separator communications step 1 PumpWorks sends out a query to available hardware In some case this query can leave unwanted characters on the communication bus These characters may cause a communications timeout when you try to initialize the separator setup Simply retry the separator setup until communications are established with the ALDM 25 42 Acoustic Level Detection Module ALDM User s Manual 2 Apply the settings shown below The Com Port setting Com8 may be different for your sys
30. rvention or threshold adjustments In addition the raw waveforms and a plot of the match quality is displayed on the video output This makes the NER ALDM one of the easiest and most reliable ultrasonic level measuring systems available 36 42 Acoustic Level Detection Module ALDM User s Manual exi New England Research Acoustic Separator Amplitude Quality reference 81 286 psec R lt q interface 445 60 psec Meter Reference Target F Fluid Interface Zoom le oo it Zoom Teale ar RA r ered ea a penta cet aaa ee Fluid Interface Reference Target Tp I eh i patie ce et heeceicae Match a Match PA r oa Fluid Interface Reference Target i Waveform Waveform a a Heavy Fluid Speed 1 1 1 1 f 1 1 Time y P Se 100 150 200 250 300 350 400 450 lt _ H microseconds c 1633 m s abs ml 353 01 brine 26 67 oil Error Code rel ml 353 01 brine Zoho oil Absolute and Ree Ok Relative Volumes processing mf on env tae ver 2 10 Figure 23 ALDM Video Screen Once the computer has located the interface signal the relative volumes are calculated and the results displayed on the screen 37 42 Acoustic Level Detection Module ALDM User s Manual 6 3 Error Messages If an error information code is present in the data packet then all other data in the packet are to be regarded as invalid If valid data has been acquired then the dat
31. s the user should prepare the inner surfaces of the separator in accordance with the cleaning and preparation instructions from separator vessel manufacturer 3 3 Accessories Supplied The following accessories are supplied with the ALDM for two and three phase separators e US style power cords three conductor length 2 5 m e One coaxial transducer cable length 6 m per active transducer e One ultrasonic transducer two phase separators or two ultrasonic transducers three phase separator e An additional spare ultrasonic transducer e Spare Viton O ring transducer seals e Hastelloy reference target e Reference target stand e BNC connector block e Serial cross over cable for a host computer link or diagnostics e User s Manual 6 42 Acoustic Level Detection Module ALDM User s Manual 4 Installation Interfacing and Safety This section contains information and instructions for installing and interfacing the ALDM as well as safety precautions It includes initial inspection procedures power and grounding requirements and installation instructions The electronics console must be located within 20 feet of the separator vessels 20 feet is the length of the special high temperature coaxial cables that connect the electronics console to the separators The electronics may be mounted in a standard 19 inch rack if desired The console may come with an optional 2 port video keyboard mouse KVM switch Th
32. s enter For the password type root without quotes as shown below in red NER embedded linux development and maintenance system Fedora Core 2 2 6 5 1 358 on an i386 Use field root login Midge login root Password root T7 Now type sepcfg to start the configuration editor NER embedded linux development and maintenance system Fedora Core 2 2 6 5 1 358 on an i386 Use field root login Midge login root Password root Last login Saturday August 18 on ttyl NER embedded linux development and maintenance system Midge sepcfg 8 The configuration editor jed appears Using the arrow keys edit the configuration file as necessary see the next section 17 42 Acoustic Level Detection Module ALDM User s Manual 9 When complete press lt Ctrl gt x then lt Ctrl gt c to save the file and exit the text editor If you made any changes that you wish to make permanent then press y at the confirmation prompt 10 At the prompt type reboot to restart the ALDM system Midge reboot Please note When the ALDM is running in Normal mode the system is operating from a read only file system The system may be shut down without damage by simply turning off the power switch When the system is in maintenance mode the computer is running with read write disk access It is very important not to power down the system by using the power switch Use the
33. seeneeats 41 CC 0 He O Ra So ete 41 AAKT A AA E AE E E AEE EEA OEN E EAA AEE EE ES 41 3 42 Acoustic Level Detection Module ALDM User s Manual 2 Table of Figures Figure 1 Removing the fuse HOlder jt act ese ce settee dees iets Doct toate te oot at 8 Figure 2 North American fuse arrangement 0 eceesceessecseeeeseeeesceceaeceseeeseeesaeeeaecnseensaee 9 Figure 3 European fuse arrangement 2 2 ee ce BE eee 9 Figure 4 Electronics console front view three phase separator version eeeeeeees 10 Figure 5 Electronics console rear view three phase separator VersiON ceeseeeeeee 10 Figure sO KVM connections esinsin e E ad tee lots uate ses Aco iat tes 10 Figure 7 Typical two phase separator Vessel cnc 3 0 ce dln ae esea tedden de 11 Figure 8 A hybrid three phase separator vessel oo ces ceeceeesceesseceseceseeesneecsaeceseenseeeeneees 12 Figure 9 Ultrasonic transducer assembly 2s28 cc2e Stott aside ita tenectiides 15 Figure 10 Two Phase Separator Serial Protocol Example ceeceeeeeseeseseceeeeeeeeeeneees 23 Figure 11 Three Phase Separator Serial Protocol Example cesceeeeseesseceeeeeeeeeeneees 24 Figure 12 PumpWorks separator communications Step 1 ee eeeeeeeeeeseeeeeeceeeeeeeeeeneees 25 Figure 13 PumpWorks separator communications step 2 essseseseeesesrrsrireresresseseresresse 26 Figure 14 View separator d tasin se isiresinresieni errn neji o a bias 26 Figure 15 ALDM Electronics C
34. t Zone o 1 W a j G h ra MV g Zone g Z Ly y Bore 7 r Input Ultrasonic Pe AN N Connection E e Figure 18 A hybrid three phase separator 30 42 Acoustic Level Detection Module ALDM User s Manual A specific purpose staggered three phase separator vessel is shown below In this configuration the separation bore is in the center and the measurement bores are isolated on either side still preserving the high quality liquid interfaces This setup preserves the same resolution as the hybrid separator however material and machining cost is reduced The three phase separator communication interface allows the implementation of a volume offset to the measurements This coupled with user specified bore diameters allows the ALDM to be configured for nearly any conceivable hardware setup See section 4 7 ALDM Software Configuration fbas ini for more details Light Fluid Output Measurement Zone ee lt o M Middle Fluid easurement Output Zone Fa upu M Bore B Ultrasonic Transducer Connection Volume Adjustment Constant VAC Heavy Fluid cue fs Mixed Fluid Bore A AIN Input Ultrasonic Transducer Connection Figur
35. t bitsperplane 16 l 20 42 Acoustic Level Detection Module ALDM User s Manual 4 8 EIA RS 232C Communication Port Communication is performed via standard asynchronous RS 232C interface operating at 9600 baud 8 bits 1 stop bit no parity no flow control Key parameters for the RS 232C link are given in Table 4 and in section 8 Serial Commands The pin out of the 9 pin RS 232C socket is as given in Table 3 RS 232C Connector Pinout Pin Number Function no connection This pin outputs data to the PC Data from the PC is to be applied to this pin no connection Ground no connection Table 3 RS 232C Connector Pinout Communication consists of l Data request which is always results in a transfer of measured values and error codes to the PC 2 Reset of relative volume reading A data request cycle is initiated when the code ENQ ASCII 0x05 or the ASCII character is received followed by a carriage return CR ASCII 0x0D ALDM responds by sequencing through a measurement cycle and returning the newly measured data together with an error message The data string is formatted as shown in Table 4 RS 232 Data Format Reset of relative volume reading is carried out on receipt of R or r ASCH 52h or 72h followed by a CR ALDM responds by resetting both relative volume readings to zero No confirmation code is returned 21 42 Acoustic Level Detection Module ALDM User s Manual Two Phase ALD
36. tem Select Enable Separator when finished Set up Separator 3 NER 5 00 ot 10 00 X New Protocol 9600 v Figure 13 PumpWorks separator communications step 2 3 You can view the current separator data by selecting Other gt Separator Data from the main menu Quizix PumpWorks eia Error Log Configure Communications Windows Help Software Pressure Transducer Calibration Auxiliary Analog Input Signals Auxiliary Digital Input Signals Auxiliary Valves Auxiliary Digital Output Back Pressure Regulator Equations and Timers NoPumps Active Data Logging OFF Sequencer OFF No Errors Figure 14 View separator data Please see the PumpWorks documentation for more information on the operation and setup of the PumpWorks software 26 42 Acoustic Level Detection Module ALDM User s Manual 5 The ALDM Console This section provides general operating information and functional identification of all controls and connectors on the ALDM unit 5 1 Front Panel Description Acoustic Seporator O O KIEF OTO Bore B FIO O O Iota Link Status CO Power Or O o wea O a g Q o fay olo olo olo olo olo al Figure 15 ALDM Electronics Console Front Panel Three Phase Separator Power ON Indicator This green indicator signifies that th
37. to overall simplified mechanical drawings or block diagrams of electronic circuits A typical two phase separator vessel is shown below Notice how the measurement bore is isolated from the separation bore preserving a high quality liquid interface The ultrasonic transducer reference target and electrical connections supplied by NER can be seen near the bottom of the measurement bore The bore diameters are user specified and may be unequal diameters The bore length is also user specified and is limited only by signal quality Vent a Light Fluid Output Separation Bore Measurement Bore Reference Target Ultrasonic Tranducer NA Ultrasonic Transducer _ Connection Inlet Mixed Fluids Heavy Fluid Output Figure 17 A typical two phase separator vessel 29 42 Acoustic Level Detection Module ALDM User s Manual A hybrid three phase separator vessel is shown below In this configuration two two phase systems are connected together This configuration enables the measurement of three different volumes while also recording the wave velocity in the two heaviest fluids The light fluid may be a gas The ultrasonic transducer reference target and electrical connections supplied by NER can be seen near the bottom of each measurement bore Light Fluid oo Light Fluid os gt Se Middle Fluid i A Z COD Heavy Fluid Measuremen
38. ule ALDM User s Manual The Error Codes for a three phase system are concatenated into a single result like so Error lt Bore A Error Code gt lt Bore B Error Code gt lt Recovered Data gt e For example a result like Error02 26839 21278167411129 212781674 Indicates that Bore A is operating correctly and Bore B has encountered an ERROR2 as described in the table above The data included in this response may not be reliable e Similarly the result below Error20 26839 21278167411129 212781674 Indicates that Bore B is operating correctly and Bore A has encountered an ERROR2 as described in the table above The data included in this response may not be reliable 39 42 Acoustic Level Detection Module ALDM User s Manual 7 Ultrasonic Transducer The ultrasonic transducer should not require any maintenance It is suggested that the unit be returned to New England Research Inc if the ultrasonic transducer needs servicing It may be necessary to cut and replace the electrical connections to the coaxial connector in order to service this component Repair of electrical connections on the ultrasonic transducer requires the use of high temperature solder 40 42 Acoustic Level Detection Module ALDM User s Manual 8 Serial Commands The ALDM listens for commands on dev ttySO configured for 9600 Baud 8 bits 1 stop bit no parity and no flow control It responds to certain command charact
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