verax 75m and verax vpa installation manual · verax 75m and verax vpa installation manual jp3...

Verax 75M and Verax VPA Installation Manual

JP3 Measurement4109 Todd LaneAustin TX 78744

512-537-8450www.jp3measurement.com

Verax 75M Installation Instructions, Rev 11 103/31/2016

Table Of Contents:

1. Facilities Requirements page 3

2. Unpacking and Handling page 5

3. Mounting the Control Panel page 7

4. Wire Verax Control Panel to Mux Panel page 9

5. Mounting the Probe Assembly page 11

6. Probe Assembly to Control Panel Connections page 13

7. Z-purge installation (Optional) Page 20

8. Heater Blanket for Probes (Optional) Page 22

9. Power Up and Commissioning Page 23

2Verax 75M Installation Instructions, Rev 1103/31/2016

1) Facilities Requirements:

Intended Use:The Verax 75M is an optical NIR analyzer for determining the constituents and physical properties of a hydrocarbon fluid stream by using NIR spectroscopy to model the parameter of interest. The 75M can monitor up to 10 read points with the same control panel. Contact a JP3 sales representative to discuss the range of analysis available. The Verax 75M-Z model incorporates a Z-purge system for mounting in a Class I / Division 2 location.

3

Location Rating:• Verax 75M Analyzer is in two Type 4 NEMA Enclosure, and all

provided fittings are Type 4 rated.• For General Purpose Location, Conforms to ANSI/UL Std 61010-

1 • For Class I / Division 2 A,B,C,D, T Code- T4 a Type Z-

pressurization must be used. With Z-purge, Conforms to NFPA Std 496

• Certified to CAN/CSA Std C22.2 No. 61010-1• Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F).

Electrical Input Requirements:• Per Customer Specification one of the two options below:

• 100-240V AC, 50-60 Hz, 1.6-0.7 Amp • Or, 24V DC, 3.5 Amp

• The input electrical configuration is indicated on the warning tag below the antenna on the left side of the box (see Figure 3)

• For surge protection a 20A breaker is recommended as the customer-provide disconnection device

Other Facilities Requirements (for Z-purge only):• Instrument Air or Nitrogen

• Supply pressure: 80-120 psig• Safe Pressure Set Point: 0.25’ water column• Safe pressure flow rate: 0.13-3.5 SCFH• Exchange Flow Rate: 4 SCFH

Verax 75M Installation Instructions, Rev 1103/31/2016

Explanation of Warning Labels:

4

The following warning applicable only when using the Z-purge option:WARNING – PRESSURIZED INCLOSUREThis enclosure must not be opened unless the area atmosphere is known to be below the ignitable concentration of combustible materials or unless all the devices within have been de-energized AVERTISSEMENT : BOÎTIER SOUS PRESSION:Ce boîtier ne doit pas être ouvert à moins que l'atmosphère de la zone ne soit inférieure à la concentration inflammable de matières combustibles ou à moins que tous les dispositifs qui s’y trouvent n’aient été mis hors tension.

The following warning applicable only when using the Z-purge option:WARNING: Power must not be restored after enclosure has been opened and until enclosure has been purged for 3.5 minutes for Verax 75-Z model or 6 minutes for Verax 75M-ZAVERTISSEMENT: L'alimentation ne doit pas être rétablie après l’ouverture du boîtier et jusqu'à ce que le boîtier ait été purgé pendant 3,5 minutes pour le modèle Verax 75-Z ou 6 minutes pour le modèle Verax 75M-Z.

The following warning applicable to all models:The model and electrical configuration on the warning label are specified with punched holes next to the applicable value.Le modèle et la configuration électrique sur l'étiquette d'avertissement sont spécifiés avec des trous percés à côté de la valeur applicable

Figure 1: Warning Label Located on the left side of the analyzer below the antenna

port. (see Figure 3)


Handling Instructions:• Verax Control Panel

• Weight: 51lbs• Dimensions: 24’’ x 30’’ x 9.35’’• Mounting Holes: 18” x 31.25”

• Mux Control Panel• Weight: 40lbs• Dimensions: 24’’ x 24’’ x 9.35’’• Mounting Holes: 18” x 25.25”

• Uncrate and mount the Control Panels and mount to unistrut or other mounting surface capable of handling the weight of the unit. Do not drop.

• The Mux Control Panel should be mounted no more than 12” below the Verax Control Panel

• If using a Z-purge 12” between panels is required to make room for the purge panel.

5

2) Unpacking and Handling:

Shipped Materials:• Verax Analyzer Control Panel (qty 1)• Mux Control Panel (qty 1)• Probe Tree Assembly (one per analysis point)• Fiber Optic Cable Pair (one pair per probe tree)• Antenna (qty 1)• Z-purge w/ fittings (optional, 1 set)

Figure 2 – Verax 75M Analyzer Control Panel - Dimensions

Verax Control Panel

Mux Control Panel

12”

24”

30”

24”18”

31.25”

25.25”


6

Figure 3 – Verax 75M Analyzer Control Panel – Front View

Spectrometer

RTDTerminal Blocks

PLC

Antenna Fitting

Radio / Modem

PCEthernetSwitch (Comm)

Wiring Terminal Blocks

Serial # & Warning Label

Incoming Power Connection

Multiplexer

TransducerTerminal Blocks

PLC Expansion Modules

Mux Terminal Blocks

Verax Control Panel

Mux Control Panel


7

3) Mounting the Control Panels:

Mounting Requirements:• Select a location that is easily accessible at grade level.• Mounting holes are provided for easy installation.• The Mux Control Panel must be mounted no more than 12” below the Verax Control

Panel.• When using a Z-purge 12” separation is required to make room for the purge panel on

the Mux Control Panel (see Section 7 for details)• Shade is required if mounting outdoors where ambient temps can exceed 90⁰ F.• Do not mount the analyzer in such a way to make it difficult to operate the customer-

provided electrical disconnect device (switch, breaker or other)

Antenna Connection:1. 16dB Antenna is provided along with a 90 degree fitting.2. Attach Antenna to the fitting on the upper left of the Analyzer Panel using the 90

degree fitting (see Figure 3 for location of the fitting).

Routing Fiber Optic Cable Between Probe Set and Mux Control Panel:Warning – Read Carefully• Fiber optic cable is extremely sensitive to sharp bend angles and contamination.

Handle very carefully to avoid kinks and keep the ends capped until ready to attach to the probes:

• Maintain a minimum 7” bend radius when running/routing the fiber from control box to probe assembly

• It is recommended that the fiber optic cable be run in its own dedicated conduit. Do not place fiber in open cable trays where it can be stepped upon.

• Keep the fiber ends capped until you a are ready to connect


8

Pass-through for Electrical Wires:• The Verax Control Panel is shipped without holes or wire ways for most of the

incoming electrical service or fiber connections. The only pre-positioned holes are:• The Antenna fitting (top left of the Verax Control Panel),• The wire pass-throughs between the Verax and Mux Control Panels (bottom

left for the top panel, top left for the mux panel).• Additional wire pass-throughs will need to be installed by the customer. The

placement of these holes is left up to the customer’s installation teams in order to provide maximum flexibility to bring the cables and fiber from below or above, and attach them to the Verax Control Panels with a sufficient size conduit or fitting.

• All connections or fittings chosen by the customer should by rated for Type 4 enclosure.

• After the wires and fibers are run, all ports and pass-throughs must be plugged with duct putty or some other standard industry practice to assure the sealed integrity of the enclosure.

• The customer must plan for the following cables when choosing the size and placement of ports on the Verax Control Panel:

• One Incoming Electrical Cable to the Top Verax Panel• One Incoming communications Cable to the Top Verax Panel• One RTD cable from each probe set to the Top Verax Panel• One Transducer cable from each probe set to the Top Verax Panel• Two Optical Fibers (send and receive) from each probe set to the Bottom Mux

Panel.• Read instructions in Section 6 regarding where these fibers/cables attach inside the

control panels before you start cutting holes.

• The customer is responsible to protect the inside of the control panel when cutting or punching holes for the wire way. DO NOT ALLOW METAL SHAVINGS TO FALL ON THE ELECTRICAL CONNECTIONS OR COMPONENTS INSIDE THE CONTROL PANEL.

• Contact your local JP3 sales representative to discuss options


9

4) Wire the Verax Control Panel to the Mux Control Panel:

Connect 4 wires from Verax to Mux Control Panels:1. The Verax 75M is shipped with 4 cables coiled in the Verax Control Panel that need to

pass through the flex conduit to the lower Mux control Panel. These are labeled:• Mux Power Cord (2-wire cable)• Spect Power Cord (2-wire cable)• Mux Comm Cable (3-wire cable)• USB Cable

2. Install the provided ½” and ¾” flex conduit between the liquid tight fittings on Mux and Verax Panels.

3. Pass the wires through the flex conduit as shown in Figure 4.4. Connect the cables to the Mux Wire Terminal Block as shown in Figure 4.

Mux Power and Spect Power

Mux Command USB

Mux Wire Terminal Block

Figure 4 – Mux Power/Comm/Ground Wiring Schematic


10

Connect the USB:1. Attach The USB cable to the back of the spectrometer, under the spectrometer cover

as shown in Figure 5. The cover does not need to removed to make the attachment.

USB port

Figure 5 – USB plug for spectrometer


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5) Mounting the Probe Assembly:

Placement:• The Probe Assembly are typically mounted to a unistrut frame, or other solid structure• Probes should be accessible at grade level.

Pressure and Temp Rating:• All probe windows and probe assemblies are tested to 1500 psi• Operational temperature range: -29C to 50C (-20⁰ F to 122⁰F).

Bypass Probe Configuration:• For a bypass probe assembly, the customer taps into the process stream they want to

monitor, plumbs the fluid to the inlet on probe assembly, and back to the process stream. (see Figure 4 on the next page)

• It is highly recommended that the customer supply a stinger at the inlet and return of the pipe you are monitoring in order to pull fluid from the center of the pipe.

• Either ½” or ¼” Swagelok fittings are supplied on the inlet and return ports of the probe assembly. Customer supplies ¼” or ½” stainless steel tubing as dictated by the fittings supplied on the probe assembly.

• ½” is typical for liquids• ¼” is typical for gas

• The customer must assure sufficient flow of liquid or gas over the probe windows by providing a pressure drop of at least 1 PSI from inlet to outlet. Choosing the correct inlet and return points on the process pipe is critical to assure flow. Often choosing inlet and return points such that flanges, valves, meters or similar instruments are located between these points is sufficient to provide the necessary bypass pressure differential.

• Actual Installation details vary by location and application; consult with JP3 Sales representative to discuss options.

• When using a heater blanket with the probe assembly, 120VAC, 2 Amp service is required. The junction box must be within 4 feet of the probe assembly.


12

3-way Return Valve

Transducer RTD

Service Port DO NOT REOME CAP

Inlet Port

Conduit Housing

Send Fiber Fittings

Figure 6 – Bypass Probe Assembly

Return

Figure 5 – Example Probe Bypass Arrangement

InletStinger at the inlet to sample from center of the pipe

Min ∆P from Inlet to Return = 1 psi

Receive Fiber Fittings

Service Port DO NOT REMOVE CAP

Top-Down View


13

6) Probe Assembly to Control Panel Connections:

Connect Fiber Optics to Probe Assembly:

Warning – Read Carefully• Fiber optic cable is extremely sensitive to sharp bend angles and contamination. Handle

very carefully to avoid kinks and keep the ends capped until ready to attach to the probes:

• Maintain a minimum 7” bend radius when running/routing the fiber from control box to probe assembly

• It is recommended that the fiber optic cable be run in it’s own dedicated conduit. Do not place fiber in open cable trays where it can be stepped upon.

• Keep the fiber ends capped until you a are ready to connect

Attach Fiber to Probe Assembly:1. Open the conduit housing on the probe assembly2. Install the fiber using LT50 fittings and flex conduit at either end of the probe assembly

(see Figure 6). The flex conduit approach offers the best protection for the fiber.3. Connect the fiber to the back of the probe inside the conduit housing by screwing the

fiber end onto the threaded probe connection. (see Figure 7)

4. DO NOT THROW AWAY THE KNURLED CAPS. These should be left in the conduit housing to be used to protect fiber and probe connections when disconnected during servicing.

5. Replace conduit housing cover

Figure 7 –Fiber Installation on

Probe Assembly

Fiber/Probe Connection Point

Liquid Tight Fitting


14

JP3 Measurement Fiber Optic Cable Specification

JP3 uses a custom optical fiber assembly, design and characterized to maximize the characteristics of the optical loop from laser to probe and back to the detector. The following are specifications important for handling and installation of the fiber:• 600um-core multimode fiber with a Kevlar jacket.• 5.5mm black PVC weather proof furcation jacket, UV resistant• Outdoor rated construction, and all components nonconductive

(most similar to OFNR indoor construction)• Weight = 22 lbs/1000 feet (3.3kg/100m)• Max Installation Tension, 180 lbs (800N)• Max Operating Tension, 90 lbs (400N)• Installation Temp Range, 15⁰ F to 176⁰ F (-9C to 80C)• Operational temp range, -40⁰ F to 122⁰ F (-40C to 50C)• Minimum Bend Radius = 7” (18cm)• Male SMA connections on both ends.• Each end will be labeled as below:

Figure 8 –Fiber Assembly dimensions and labeling


15

Attach Fiber Optics to Mux Control Panel:1. Two Optical Fiber from each probe assembly are connected to the Multiplexer in Mux

Control Panel.2. Pass the fibers into the Mux Control Panel through customer-provided pass-through.3. Send Fibers are connected to the to the right face of the Multiplexer, receive fibers are

connected to the left side of the Multiplexer4. Each analysis or measurement point is assigned a number 1-10. The connections are

numbered on the Multiplexer face. Send fibers from number 1 should be paired with the receive fiber from number 1, number 2 to number 2, and so on.

5. Connect the send fibers to the right face by screwing the SMA connector to the threaded connection on the Multiplexer. The SEND fibers will be labeled “SEND” using 2” Red Shrink Tube at both ends.

6. Connect the receive fiber to the left face by screwing the SMA connector to the threaded connector on the Multiplexer. The receive fibers will be labeled “RECEIVE” using 2” Yellow Shrink Tube label at both ends.

7. DO NOT THROW AWAY KNURLED CAPS FROM THE FIBER OR THE Multiplexer. These are needed to protect the connections during servicing. A box for storage of the caps is provided in the bottom of the Mux Control Panel.

Receive Fiber Connections

Send Fiber Connections

Multiplexer

Figure 9 –Fiber Connections to the

Multiplexer in the bottom of the Mux Control Panel

analysis points are numbered 1-10

Center Port Fiber goes to the spectrometer (already connected)


16

Wire the Probe Assembly to the Verax Control Panel:

Attach RTD Cable to Control Panel1. At the probe assembly connect the RTD wires to the customer provided

electrical cable.2. At the Verax Control Panel run the RTD cables through customer-provide wire

pass through port (see section 3) and route to the terminal blocks on the left side of the panel.

3. Each analysis point is assigned a number (the same number assigned to the fiber from that analysis point), and the terminal blocks are labeled numbers 1-10

4. Connect the RTD cable from number 1 to the terminal block for number 1 as in Figure 10. Continue likewise with subsequent numbers.

• one red wire to the top terminal tier• the other red wire to the middle terminal tier• the white wire to the bottom terminal tier

Figure 10 –RTD and Transducer Wiring Instructions


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Attach Transducer Cable to Verax Control Panel1. At the probe assembly connect the Transducer wires to the customer provided

electrical cable.2. At the Verax Control Panel run the Transducer cables through customer-provide

wire pass through port (see section 3) and route to the terminal blocks on the right side of the panel.

3. Each analysis point is assigned a number, and the terminal blocks are labeled numbers 1-10

4. Connect the Transducer cable from number 1 to the terminal block for number 1 as in Figure 11. Continue likewise with subsequent numbers.

• Red wire on the top terminal tier• Black on the second terminal tier• Brown on the third terminal tier• Gray on the bottom terminal tier

Figure 11 –RTD and Transducer Wiring Instructions


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Connect the Ethernet Communications Cable to Verax Control Panel:1. Run the Ethernet communications cable through customer-provide wire pass

through port and route to the Ethernet switch on the right side of the analyzer control panel. ( See Figure 3)

2. Connect to any available Ethernet port

Connect Main Power to Verax Control Panel:For 24V DC Power Configuration1. Run the power cable through customer-provide wire pass through port and route

to the terminal blocks on the upper right side of the analyzer control panel. ( See Figure 3)

2. Connect hot wire to 24V fuse3. Connect neutral wire to 0V terminal

Figure 12 –Main 24VDC Power Wiring Instructions Components shown inside

dotted line only included with100-240V AC option


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For 100-24VAC Power Configuration1. Run the power cable through customer-provide wire pass through port and route

to the terminal blocks on the upper right side of the analyzer control panel. ( See Figure 3)

2. Connect hot wire to 100-240V fuse3. Connect neutral wire to 0V terminal4. Connect ground wire to the green/yellow ground terminal

Figure 13 –Main 100-240VAC Power

Wiring Instructions

Components shown inside dotted line only included with100-240VAC input option


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7) Z-Purge Installation (optional):

Warning – Read Carefully• You must install the Z-purge if the Verax 75M will be in a Class I / Division 2

Hazardous location.• Consult Pepperl-Fuchs website to confirm the below arrangement for panel, pluming,

and blow-off valve given specific conditions for your plant.

Installation:• Mounting Configuration and Pipe Routing are shown below in Figures 14 and 15. All

fittings are ¼”

Figure 14 – Pipe Fitting

Schematic, (Viewed from

back of Mux Control Panel)


21

Figure 15 – Z-Purge Hardware

Configuration


22

7) Probe Heater Blanket (optional):

Installation:• Heater blankets are designed to wrap around the sample cell cross to keep the probes

warm and free of paraffins.

Electrical:• Heater blankets use Thermon self-regulating 12W/ft heating tape• 2Amp, 120V AC electrical service• A 5’ pigtail is provided using ½” flex conduit.

Figure 16 – Heater Blanket


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Figure 17 –Power up sequence

8) Power-up and Commissioning:

Power Up Sequence:• To Engage Power engage the fuses in the following order

1. 100-240V fuse (if applicable – for AC configuration only)2. 24V fuse (Powers PLC Modules, Switch, and Multiplexer)3. 12V (Powers PC and Radio)4. Last 12V fuse (Pwers Spectrometer)

1st2nd3rd4th

• At this point the Verax 75M Analyzer is ready to be commissioned. Contact JP3 Field Service team to complete installation and commissioning.

• Contact JP3 Field Service team for all maintenance and servicing needs• [email protected]• 512-537-8450

mailto:[email protected]

verax 75m and verax vpa installation manual · verax 75m and verax vpa installation manual jp3...

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