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CHALLENGE

ACCEPTED

Non-Intrusive Signaller

Ultrasonic Active Topside

Operating Manual

The ID5000A is a fully ATEX certiﬁed,

non-intrusive pig signaller which detects,

signals and logs the passage of pigs at

critical points along the pipeline both on land

and off shore

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 1 of 21

ID5000A_5001

Rev

Date

Summary of change

A00

08/08/17

CR00485: Was ID5000A MANUAL RevB02. CR00380: Address change.

CR00499: Front cover update.

A01

12/10/17

CR00499: Cover page update

A02

28/07/20

CR00800: Email address and Notified Body Number updated.

A03

15/10/20

CR00947: New Front Page. Section 9 updated.

COMMENTS:

ONLINE ELECTRONICS LTD 
ID5000A_5001_A03 Page 2 of 21 
CONTENTS Page 
 
GENERAL DESCRIPTION ......................................................................................... 3 
SYSTEM SPECIFICATION ........................................................................................ 4 
OPERATION .......................................................................................................... 5 
1. TURN ON SEQUENCE.......................................................................................... 5 
2. DETECTION MODE 0 .......................................................................................... 6 
3. SINGLE BUTTON MENU INTERFACE...................................................................... 7 
3.1. STATUS ........................................................................................................ 7 
3.2. VIEW EVENTS ............................................................................................... 7 
3.3. DELETE ALL EVENTS ...................................................................................... 8 
3.4. MODE1 SETUP ............................................................................................... 8 
3.5. SHUTDOWN .................................................................................................. 8 
3.6. SAVE GAIN AND PW ....................................................................................... 8 
3.7. MODE0 DETECT ............................................................................................. 8 
3.8. ADJUST GAIN UP ........................................................................................... 8 
3.9. ADJUST GAIN DOWN...................................................................................... 8 
3.10. AJST PULSE WIDTH........................................................................................ 8 
3.11. SET DETECT COUNT....................................................................................... 9 
3.12. SET INDICATOR DELAY .................................................................................. 9 
3.13. SET MINIMUM DIAMETER................................................................................ 9 
3.14. SET TIME...................................................................................................... 9 
3.15. SET DATE ..................................................................................................... 9 
3.16. SET TRIG DELAY.......................................................................................... 10 
3.17. SET FILTER ................................................................................................. 10 
3.18. SET CONFIG................................................................................................ 10 
4. SETUP MODE 1................................................................................................ 11 
4.1. ZOOM AND RULER ....................................................................................... 12 
4.2. THRESHOLD LEVELS .................................................................................... 12 
4.3. DETECTED DIAMETER .................................................................................. 12 
4.4. GAIN.......................................................................................................... 12 
4.5. PULSE WIDTH ............................................................................................. 12 
4.6. SWITCH FUNCTION...................................................................................... 13 
4.7. DETECT VALUE ............................................................................................ 13 
5. BATTERY INDICATOR ....................................................................................... 13 
6. DETECTION ALGORITHM................................................................................... 14 
INSTALLATION .................................................................................................... 15 
1. MAIN HOUSING INSTALLATION ......................................................................... 15 
2. TRANSDUCER INSTALLATION............................................................................ 16 
3. PARAMETER SETUP .......................................................................................... 17 
RECOMMENDED MAINTENANCE ............................................................................. 18 
1. MAIN BATTERY REPLACEMENT........................................................................... 18 
EXTERNAL CONNECTIONS .................................................................................... 19 
1. STANDARD TERMINAL PCB ............................................................................... 20 
WARRANTY ......................................................................................................... 20 
DISPOSAL OF UNIT.............................................................................................. 20 
ATEX APPENDIX .................................................................................................. 21 
 
 

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 3 of 21

1. GENERAL DESCRIPTION

The ID5000A (Active) Ultrasonic pig signaller is a fully ATEX certified, non-intrusive, pig

signaller which detects, signals, and logs the passage of pigs at critical points along fluid filled

pipelines both on land and offshore.

The signaller uses the pulse-echo method to detect the time of flight of ultrasonic pulses

through the pipe. An ultrasonic pulse is sent through the pipe wall and provided that an

acoustically transparent column of fluid is passing through the pipe (single phase, no gas

bubbles, no large solid particles), the unit is able to see a “reflection” of energy from the other

side of the pipe. When a pig passes, the fluid path is disturbed, removing the reflection, and

the pig is detected.

Events are signalled as they occur via a 2.7” graphical display and high brightness LEDs

positioned around the perimeter of the display. Events can also be signalled remotely using

several optional outputs.

The unit logs the time and date of up to 100 events which can be viewed at any point using

the local display. The user can turn the unit ON and OFF as well as modify several settings

using a single control button and intuitive menu system.

The unit has two basic parts as shown below. The transducer is permanently connected to the

main housing via a cable. The transducer is screwed into a mounting block which can be

quickly and easily attached to the pipeline using ratchet straps or steel banding. The main

housing contains all electronics, battery (if fitted), display and the control button. The main

housing is mounted onto the pipeline using a mounting block and straps in a similar fashion to

the transducer.

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 4 of 21

2. SYSTEM SPECIFICATION

GENERAL

Battery Type .....................................................15V Alkaline Non-Rechargeable Battery Pack

Battery life LISTENING at +20°C (from 15V Alkaline Non-Rechargeable Pack)............ 120 Days

Rechargeable Battery Type ........................................... 12V NiMH Rechargeable Battery Pack

Battery life LISTENING at +20°C (from 12V NiMH Rechargeable Battery Pack).............12 Days

External Supply................................................................................................... 24.0VDC

Ambient Temperature Range .................................................. See section 9 ATEX APPENDIX

ATEX Code.................................................................................. II 2 G Ex d mb IIC T5…T6

EC Type Examination Certificate Number ................................................. TRL08ATEX21161X

Housing Material (SS Unit Only) ............................................................316L Stainless Steel

Housing Material (Al Unit Only) .................................. Copper Free Aluminium Alloy LM25 (Al)

Transducer Material .............................................................................316L Stainless Steel

Weight in Stainless Steel ........................................................................................... 15kg

Weight in Aluminium.............................................................................................. 11.5kg

OUTPUTS

SPDT Relay Outputs (Volt Free Contacts).................................2A @ 30VDC / 0.5A @ 125VAC

Current Loop Output ................. 5.0mA ±1.0mA (LISTENING) / 19.0mA ±1.0mA (DETECTION)

Logging .............................................................................. 100 Events with Time and Date

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 5 of 21

3. OPERATION

The Special Conditions for Safe Use detailed in section 9 ATEX APPENDIX must be observed

and followed at all times.

3.1. TURN ON SEQUENCE

To turn the unit on simply press and hold the control

button until the company logo appears on the display

and then release, this takes approximately 5 seconds.

The next screen shows the product logo. This screen

will be displayed for 5 seconds as shown by the

counter at the bottom left corner of the display.

When the countdown indicator at the bottom left of

the screen reaches zero, or the control button is

pressed, the next screen will appear.

The next screen shows the time and date currently

set in the unit.

The next screen indicates that the unit is trying to

detect the pipe diameter. While this screen is visible

the unit is shooting ultrasound into the pipe several

hundred times per second and from the received

reflections is calculating the diameter. A switch press

at this stage will have no effect. After the unit is

finished it will display the DETECTED DIAMETER

screen.

The distance in the centre of this screen shows the

average diameter which the unit detected. The next

line gives an idea of the quality of this signal path

between 00-99%. The measured diameter should be

very close to the external diameter of the pipeline but

will vary slightly due to pipe wall thickness and the

type of fluid in the pipe. Factors which could cause a

poor signal quality include how well the transducer is

coupled to the pipe surface, foreign particles within

the pipe fluid, gas bubble within the pipe fluid or non-

uniform pipe wall material.

While on the DETECTED DIAMETER screen, to re-

detect the pipe diameter, the switch can be pressed

before the counter reaches zero. If the counter

reaches zero the unit will enter DETECTION MODE 0.

See section 3.2 DETECTION MODE 0.

PRESS/

TIMEOUT

PRESS/

TIMEOUT

PRESS/

TIMEOUT

DE TECT ED DI AM ETER

028cm

GO OD SI GNAL 99%

3 PR ES S TO RE SE T

15:34:55

28/04/15

DETECTING DIAMETER…

ID5000

PIG DETECTOR

PRESS

DETECTION

MODE 0

TIMEOUT

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 6 of 21

3.2. DETECTION MODE 0

Whilst in DETECTION MODE 0 nothing is visible on the display itself however the LEDs around

the perimeter of the window will flash once every 5 seconds to indicate that the unit is alive

and waiting in this mode for a pig passage. There are 2 events that will cause the unit to react:

PIG DETECTION: If a pig passage occurs then the unit will immediately log the event time

and date to its internal memory. It will then turn the display on and show a PIG DETECTED

message with event time and date. The LEDs will start flashing every second to give a long

range indication of the pig passage.

The length of time which the unit keeps indicating the pig passage in this way is determined by

the INDICATOR DELAY value. See section 3.3.12 SET INDICATOR DELAY for a description of

this parameter and how to alter its value.

SWITCH PRESS: A single, short press of the switch will enter the display menu interface

described in section 3.3 SINGLE BUTTON MENU INTERFACE.

If the unit is not properly calibrated to a pipeline then it may repeatedly signal a PIG

DETECTED message. If this is the case then while the pig passage is being signalled press the

switch once then immediately press again and hold for approximately 3 seconds. This will enter

the display menu where SETUP MODE 1 should be selected and then refer to section 4.3

PARAMETER SETUP to calibrate the unit to the pipeline.

DE TECT ED DI AM ETER

028cm

GO OD SIGN AL 99%

3 PR ES S TO RE SE T

DETECTING DIAMETER…

PL EASE M AKE SELECTION

=> EXIT

ST AT US

VI EW EVENTS

DE LE TE ALL E VENTS

MO DE 1 SET UP

SH UT DO WN

PRESS

DETECTION

MODE 0

TIMEOUT

EXIT

PRESS

PIG

DETECTED

15 :45: 55 28/04/15

PRESS/

TIMEOUT

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 7 of 21

16 :08: 55 28/ 04/15

PI PE DIAM ET ER 02 8cm

ST ORED EVEN TS 009

LS T 28 /04/ 15 16: 00:05

ST ORED G AIN 99

IN D DELAY 00: 10:59

DE TECT ION C OU NT 50

28 /04/ 15 16: 08:55

EVENT064

28/04/15

16:00:05

3.3. SINGLE BUTTON MENU INTERFACE

While in DETECTION MODE 0, the control button can be pressed at any point to enter the

menu interface. While in the menu interface, the unit will ignore all pig passages. From the

menus the user can configure several parameters which are discussed in this section.

To enter the menu interface from SETUP MODE 1 a long press on the control button is required

as per section 3.4 SETUP MODE 1.

Note that the menus entered from DETECTION MODE 0 and SETUP MODE 1 contain different

items. All items are covered by the following sections and each section indicates whether the

item is accessed from DETECTION MODE 0 or SETUP MODE 1.

While in the menu system, every time the user presses the control button the => cursor will

move down one line and the timer at the bottom left of the screen will be reset to 5. Once the

cursor is pointing at the desired item the user simply allows the timer to reach 0 and the

selected item will be executed. This simple behaviour is used throughout the menu interface to

modify settings and interact with the unit.

To modify parameters, simply follow the instructions provided on the screen. All parameters

are incremented by pressing the control button until they are at the desired value then

allowing the timer to reach 0.

If you do not wish to modify a parameter then simply allow the timer to reach 0 without

operating the control button. The menu system is designed so that the unit will always EXIT if

the control button is left released for a long enough time.

3.3.1. STATUS

Accessed from DETECTION MODE 0. Selecting this item

shows current time and date, pipe diameter detected, the

number of stored events, the date and time of the last

event, stored gain value, current indicator delay, and the

detection counter setting.

When the counter indicator reaches zero the screen will go

blank and the unit will start looking for a pig passage

again. If the user wants to pause the screen to read it they can press and hold the switch to

pause the timer.

3.3.2. VIEW EVENTS

Accessed from DETECTION MODE 0. Selecting this item

allows the user to scroll through logged event data. If no

data has been logged then a NO EVENTS message will be

displayed.

The events are displayed one at a time from newest to

oldest. At the very top of each display the current date and

time are shown. Below this the event number is shown with

the event date and time. If the switch is pressed before the counter reaches zero the screen

will show the next event. If the counter reaches zero then the display will switch off and the

unit will return to DETECTION MODE 0.

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 8 of 21

3.3.3. DELETE ALL EVENTS

Accessed from DETECTION MODE 0. Selecting this item will display the message *WARNING*

PRESS TO ERASE ALL EVENTS. If the user wishes to delete all logged data then they should

press the switch once before the counter reaches zero. If they do not wish to erase all logged

data then simply allow the counter to reach zero without pressing the switch.

3.3.4. MODE1 SETUP

Accessed from DETECTION MODE 0. Selecting this item leaves DETECT MODE 0 and enters

SETUP MODE 1. See section 3.4 SETUP MODE 1.

3.3.5. SHUTDOWN

Accessed from DETECTION MODE 0. Selecting this item switches off the unit. When the

counter reaches zero the display will go blank and the LEDs will flash once. All logged events

and parameters will still be available when the unit is next switched on.

3.3.6. SAVE GAIN AND PW

Accessed from SETUP MODE 1. This saves the current GAIN and PULSE WIDTH values

configured from within SETUP MODE 1. This should be done whenever any changes are made

to the GAIN and PULSE WIDTH values from within SETUP MODE 1 which are to be stored. If

this is not done then any changes to GAIN and PULSE WIDTH will be lost if SETUP MODE 1 is

exited.

3.3.7. MODE0 DETECT

Accessed from SETUP MODE 1. Selecting this item leaves SETUP MODE 1 and enters DETECT

MODE 0. If the SAVE GAIN AND PW item was not selected prior to this then any changes to

their values will not be saved.

3.3.8. ADJUST GAIN UP

Accessed from SETUP MODE 1. This item changes the function of the switch to increment

GAIN. The unit will return to SETUP MODE 1 after choosing this option and every short press of

the switch will increment the gain value. Once GAIN is set the SAVE GAIN AND PW option

should be selected.

3.3.9. ADJUST GAIN DOWN

Accessed from SETUP MODE 1. This item changes the function of the switch to decrement

GAIN. The unit will return to SETUP MODE 1 after choosing this option and every short press of

the switch will decrement the gain value. Once GAIN is set the SAVE GAIN AND PW option

should be selected.

3.3.10. AJST PULSE WIDTH

Accessed from SETUP MODE 1. This item changes the function of the switch to adjust PULSE

WIDTH. The unit will return to SETUP MODE 1 after choosing this option and every short press

of the switch will increment the pulse width value. Once the pulse width is set the SAVE GAIN

AND PW option should be selected.

ONLINE ELECTRONICS LTD

ID5000A_5001_A03 Page 9 of 21

3.3.11. SET DETECT COUNT

Accessed from SETUP MODE 1. DETECT COUNT controls how easy or hard it is for the unit to

be triggered. It is available as a setting to allow the unit to discriminate between a pig passage

and a spurious loss of signal caused by for example gas bubbles passing the transducer. The

unit transmits 100 pulses through the pipe every second. If DETECT COUNT is set to 01 then if

one of these pulses does not get reflected back then a pig passage is assumed. If DETECT

COUNT is set to 255 then 255 consecutive pulses would have to be missed before a pig

passage is assumed, meaning the signal was removed for 2.55 seconds. The table below

shows recommended values for a range of pipe sizes assuming a spherical pig (i.e. worst

case) with speed of 10 metres per second or 1 metre per second. See section 3.6 DETECTION

ALGORITHM for more information.

PIPE DIAMETER

DETECT COUNT

(PIG SPEED 10m/s)

DETECT COUNT

(PIG SPEED 1m/s)

6” (15.24cm)

12” (30.48cm)

24” (60.96cm)

36” (91.44cm)

48” (121.92cm)

120

3.3.12. SET INDICATOR DELAY

Accessed from SETUP MODE 1. This parameter determines how long the unit will signal a PIG

DETECTION for. See section 3.2 DETECTION MODE 0.

The INDICATOR DELAY can be set between 00:00:00 and 99:99:99 in HH:MM:SS format. Note

that the time entered will be the time that the LEDs will flash every second for. The seconds

field will be the total number of seconds which the display shall show the pig detection time

and date for. E.g. if INDICATOR DELAY is set to 01:59:60 the unit will flash every second for 2

hours and for the first 60 seconds of this time it will show the pig passage time and date on

the display.

3.3.13. SET MINIMUM DIAMETER

Accessed from SETUP MODE 1. The MINIMUM DIAMETER value determines how long the unit

shall wait for after it transmits a pulse before it looks for a reflection. Basically it allows the

user to force the unit to ignore any spurious signals which take place between the transmit

pulse and the reflected signal.

The first signal received after the MINIMUM DIAMETER value which has amplitude greater than

the threshold level shall be measured and if it is within 2cm of the pipe diameter a ‘good’

reflection will be assumed. Normally a minimum echo value which is approximately 33% of the

pipeline diameter will be sufficient. E.g. is pipe is 30cm diameter then a value of 10cm for

MINIMUM DIAMETER will suffice.

If the transmit pulse is not dying away quick enough or there are significant spurious echoes

present then choosing a larger MINIMUM DIAMETER value may be required but it should never

be set within 6cm of the actual pipe diameter.

3.3.14. SET TIME

Accessed from SETUP MODE 1. This option allows the user to set the internal system time.

3.3.15. SET DATE

Accessed from SETUP MODE 1. This option allows the user to set the internal system date.

Indice

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