nal Dec. 2007
T
M
Differential Pressure Charger
Installation - Operation - Maintenance
Manual
PGI International, Ltd.
Excellence Through Innovation
PATENT PENDING 2 of 28
Form IOM-DB1, Revision 04
© PGI International Dec. 2007
Table of Contents
Introduction to the DB1 ....................................................................................... 3
DB1-10/20 Features............................................................................................. 4
Optional Equipment ............................................................................................. 5
Accessories .......................................................................................................... 5
Factors That Affect the Start-Up of the DB1 ....................................................... 6
Factors That Affect the Performance of the DB1 ................................................ 6
Specifications....................................................................................................... 7
Diagnostics .......................................................................................................... 7
DB1 Charger System Overview........................................................................... 8
DB1 Controller ............................................................................................. 9
LEDs............................................................................................................. 9
Interface ........................................................................................................ 9
Alarm Contacts ............................................................................................. 9
Differential Pressure Graph ............................................................................... 10
Installation
DB1 Installation................................................................................................. 11
Field Wiring Connections .................................................................................. 13
Operating Instructions
Preparing for Start-Up........................................................................................ 14
Before Starting................................................................................................... 21
Starting the DB1 ................................................................................................ 21
Shutting Down the DB1..................................................................................... 22
To Test the Charger ........................................................................................... 23
Maintenance/Trouble Shooting
............................................................................................... 24
Warranty ............................................................................................................ 27 Form IOM-DB1, Revision
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© PGI International Dec. 2007
Introduction to the DB1
The DB1 Differential Pressure Charger is an efficient and reliable alternative to solar
panel systems that are used to power electronic instruments on gas pipelines. In
applications where a lead acid battery is used to provide high peak power for short
burst requirements (such as for wireless communications at remote monitoring sites),
the DB1 produces a 12 or 24 volt power output to keep the battery fully charged.
The batterys temperature and charge level are continuously monitored and the DB1
produces up to 20 watts to keep it charged.
Unlike solar panels, the DB1 can be installed in almost any location where adequate
differential pressure exists, and is unaffected by shade, snow, freezing rain, ice, dust
build-up, or birds.
The DB1 battery charger uses the differential
pressure developed across a pressure reducing
device on natural gas pipelines to run a small
turbine-powered Generator. The Generator
output can be used to charge a lead acid battery
similar to PGIs Thermo-Electric Chargers
(TECs). Unlike the TECs, the DB1 does not
consume any natural gas. Power is produced
by allowing a small portion of the gas to flow
through a turbine, bypassing the pressure
reducing device. The amount of gas flow
through the DB1 turbine is low relative to the
total line flow, and stable, keeping the DB1
transparent to the pressure.
The pressure reducing device automatically
adjusts for the slight decrease in flow resulting
when the DB1 runs.
The power generated is micro-processor controlled to provide the ideal temperature
compensated battery charging current and voltage to the battery. Internal diagnostics
detect possible system problems and the system status can be remotely monitored
using the open collector alarm output.
Controlled start-up for the DB1 makes turning the system ON as simple as flipping a
switch. Powered by natural gas to
1440 PSIG system pressures Microprocessor controlled
simple start up and
diagnostics Integrated temperature
compensated charger with
remote battery temperature
sensor User configurable operating
characteristics Status output for remote
monitoring Controller firmware is field
upgradeable Direct mount (on pipeline) or
optional 2 pipe mount 4 of 28
Form IOM-DB1, Revision 04
© PGI International Dec. 2007
DB1-10/20 Features
10 or
20 watts of charging power Charge either 12 volt or 24 volt batteries (detected and set by the Controller) Input to allow a switch or remote device, such as an Emergency Shut-Down
Device (ESD), to disable the system signal may need to go through a barrier if
connected to an intrinsically safe device in the hazardous location (The ESD is a
failsafe feature which allows for remote activation/deactivation of the DB1.) Temperature compensated charging Status LED:
1. Idle flash GREEN (on ¼ sec off for 2 seconds)
2. Charging GREEN
3. Disabled (ESD) flash RED (on ¼ sec off 2 seconds)
4. Battery too low to start charger off
5. Shutdown flash RED (on for ½ sec off for ½ sec) Run/Disable switch Run command regardless of battery voltage Two configurable alarm outputs (open collector) with major and minor levels
(Major Alarms disable the Charger, while Minor Alarms simply alert the
technician to undesirable conditions which could require service) Lost Generator Communications Link (MAJORNon-Latched) ESD Input Detected (MAJORNon-Latched) Control Valve is Full Open but no RPM Detected (MAJORLatched) Control Valve Failed (MAJORLatched) Generator RPM or Voltage Output Too High (MAJORLatched) Controller Switch in Disable Position (MINORNon-Latched) Unable to Generate Maximum Power with Control Valve Full Open
(MINORLatched) Unable to Maintain Full Charge with Control Valve Full Open (MINOR
Latched) Generator Run Time Service Due (MINORLatched) Temperature Sensor Malfunction (MINORNon-Latched) Form IOM-DB1, Revision
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© PGI International Dec. 2007 Alarm LEDs
1. No alarm (OFF)
2. Minor alarm (Warning: DB1 can still function) flash YELLOW
3. Major alarm (DB1 is shutdown) flash RED (on ¼ sec, off 1 sec) Event log with battery volts, date, and time stamp (1,000 events) Start time Stop time Alarms Remote shutdown Run/Disable switch was switched Run or Disable commands were turned on and off Cable cut or interface malfunction shutdown. Lost communication link. Turbine maintenance log and maintenance timer to track service due Allow settings and logs to be uploaded to a PC and then downloaded to a new
Controller board Allow same configuration file to be downloaded to multiple DB1 units Safely shutdown turbine if any wires between the Generator and Controller are
cut or disconnected or if the battery is disconnected Controller can be Velcro mounted
Models DB1-10: 10 Watt Max. DB1-20: 20 Watt Max.
Options VCH Option:
Carbon Steel Remote Mount Kit VSH Option:
Stainless Steel Remote Mount Kit
Accessories SK-DB1-001
DB1 Monitor Software and Interface Cable P8-214-A0
3/4 NPT Pipe Union P8-215-C0
1/2 316SS Ball Valve SS-C9E-500-CL 0-2000psi Gauge SS-C9E-516-CL 0-300psi Gauge SS-C9E-517-CL 0-600psi Gauge SS-C9E-518-CL 0-1000psi Gauge
All gauges are 316ss, Liquid Filled, , 1/4 MNPT Center Back Mount,
with a 2 ½ Dial. 6 of 28
Form IOM-DB1, Revision 04
© PGI International Dec. 2007
Factors That Affect Start-Up of the DB1
The DB1 system start-up is dependant upon several factors. What follows is a list of
conditions that must be met in order to ensure reliable operation. Failure to meet these
conditions will result in failure to start or improper operation. Repeated attempts at
start-up may drain the battery voltage to a level below the start-up requirement (10v for
a 12v system & 20v for a 24v system).
1. An adequate pressure differential
A minimum pressure differential of 75psig is required to operate the DB1at 10 watts
(105psig to operate the DB1 at 20 watts). The power output will drop as the
differential pressure is reduced. The turbine could stall if the differential pressure is
less than 50 psig. The maximum inlet pressure is 1440 psig.
2. A properly sized battery
A properly sized battery is necessary to get the optimum performance from the DB1.
If the battery is too small, it will drain and charge very quickly. This would lead to
short ON/OFF cycling of the DB1 and appreciably reduce battery life.
3. Properly charged battery
A drained battery may not provide enough voltage to allow communication between
the Controller and the Generator. If the battery voltage is less than 10 volts for a 12
volt system, or less than 20 volts for a 24 volt system, re-charge or replac