IONX Technical Data IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com WSN-4 Series Sensor Installation Manual Document Number: 303506 Revision: C IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 1 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Contents 1. Precautions and Preparation .................................................................................................. 3 2. Initiating the WSN-4 Series Sensor ........................................................................................ 5 3. Testing the WSN-4 Series Sensor .......................................................................................... 6 4. Miscellaneous ........................................................................................................................ 6 Appendix 1 WSN-401 Installation ............................................................................................... 7 Required Tools/Materials ........................................................................................................ 7 Supplied Materials .................................................................................................................. 7 Installing the WSN-401 inside hatch ....................................................................................... 8 Appendix 2 WSN-407 Installation ..............................................................................................11 Required Tools/Materials .......................................................................................................11 Supplied Materials .................................................................................................................11 Installing the WSN-407 ..........................................................................................................12 Appendix 3 WSN-413 Installation ..............................................................................................13 Appendix 4 WSN-414 Installation ..............................................................................................17 Required Tools/Materials .......................................................................................................17 Supplied Materials .................................................................................................................18 Preparing the Tank Car Jacket ..............................................................................................19 Appendix 5 WSN-415 Installation ..............................................................................................21 Required Tools/Materials .......................................................................................................21 Supplied Materials .................................................................................................................21 Installing the WSN-415 ..........................................................................................................22 Appendix 6: Compliance Requirements ....................................................................................23 Appendix 7: Declaration of Conformity ......................................................................................24 IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 2 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com These instructions are not designed to imply or replace any operating or safety rules. It is the responsibility of the installer to understand and follow all company safety practices. 1. Precautions and Preparation WARNING In order to comply with hazardous classification, only those items specifically listed can be used and must be used only as shown. Substitution of components may affect intrinsic safety. WARNING Installation shall be carried out in accordance with the applicable code of practice by suitably-trained personnel. WARNING Repair of this equipment shall be carried out in accordance with the applicable code of practice. WARNING Any machining, drilling, grinding, sanding and/or welding related to the installation of this system should be pre-approved by the authorized department before work is started. WARNING If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection is not compromised. WARNING RF Device: Unit cannot be painted or coated with any material. Coating can adversely affect the performance of the device. Unit shall be masked appropriately if post installation coating is required. WARNING EXPLOSION HAZARD: The equipment temperature Class is T4 and only certified for use in ambient temperatures in the range Product is rated from -40C to +55C and should not be used outside this range in an explosive environment. WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD: Under certain extreme circumstances, the non-metallic parts incorporated in the enclosure of this equipment may generate an ignition-capable level of electrostatic charge. Therefore the equipment shall not be installed in a location where the external conditions are conducive to the build-up of electrostatic charge on such surfaces. This is particularly important if the equipment is installed in a zone 0 location. WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD: Suitable for hose down cleaning only. Do not clean unit with a dry cloth. Static can be generated when two dry parts are rubbed together. WARNING Products contain Primary Lithium batteries. Proper disposal procedures are required at end of life conditions. Use local regulatory disposal method for lithium Thionyl chloride batteries. For example, disposal procedure 49 CFR 173.185 or Battery Directive 2006/66/EC. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 3 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 1. Avertissements Ces instructions ne sont pas conues pour impliquer ou remplacer des rgles d'utilisation ou de scurit. Il est de la responsabilit de l'installateur de comprendre et de suivre toutes les pratiques de scurit de l'entreprise. Instructions compltes pour utiliser CMU en franais en attente. AVERTISSEMENT Afin de se conformer la classification des matires dangereuses, seuls les lments spcifiquement numrs peuvent tre utiliss et doivent tre utiliss uniquement comme indiqu. La substitution de composants peut affecter la scurit intrinsque. AVERTISSEMENT L'installation doit tre effectue conformment au code de pratique applicable par du personnel dment form. AVERTISSEMENT La rparation de cet quipement doit tre effectue conformment au code de pratique applicable. AVERTISSEMENT Tout usinage, perage et / ou ponage li l'installation de ce systme doit tre pralablement approuv par le service autoris avant le dbut des travaux. AVERTISSEMENT Si l'quipement est susceptible d'entrer en contact avec des substances agressives, il est de la responsabilit de l'utilisateur de prendre les prcautions appropries qui empchent qu'il soit affect de manire ngative, garantissant ainsi que le type de protection n'est pas compromis. ATTENTION Dispositif RF: L'unit ne peut tre peinte ou revtue d'aucun matriau. Le revtement peut nuire aux performances de l'appareil. L'unit doit tre masque de manire approprie si un revtement post-installation est requis. ATTENTION DANGER D'EXPLOSION: La classe de temprature de l'quipement est T4 et seulement certifie pour une utilisation des tempratures ambiantes. Le produit est valu de -40C +
55C et ne doit pas tre utilis en dehors de cette plage dans un environnement explosif. ATTENTION DANGER D'EXPLOSION: L'installation doit tre effectue conformment au code de pratique en vigueur par du personnel qualifi. ATTENTION DANGER DE CHARGE LECTROSTATIQUE POTENTIEL: Dans certaines circonstances extrmes, les pices non mtalliques incorpores dans l'enveloppe de cet quipement peuvent gnrer un niveau de charge lectrostatique capable d'amorage. Par consquent, l'quipement ne doit pas tre install dans un endroit o les conditions externes favorisent l'accumulation de charges lectrostatiques sur ces surfaces. Ceci est particulirement important si l'quipement est install dans un emplacement de la zone 0. ATTENTION DANGER DE CHARGE LECTROSTATIQUE POTENTIEL: Convient uniquement au nettoyage par tuyau. Ne nettoyez pas l'appareil avec un chiffon sec. Statique peut tre gnr lorsque deux parties sches sont frottes ensemble. ATTENTION Les produits contiennent des batteries au lithium primaire. Des procdures d'limination appropries sont requises en fin de vie. Utiliser une mthode d'limination rglementaire locale pour les piles au lithium-chlorure de thionyle. Par exemple, procdure d'limination 49 CFR 173.185 ou Directive 2006/66/CE. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 4 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 2. Initiating the WSN-4 Series Sensor Note: Before beginning, make sure to complete the instructions for activating the CMU and initiating the Wireless Sensor Monitor. Section 1:
1. For WSN-4 Series Sensors not supplied with a magnet taped to the chassis proceed to Section 2. 2. Remove the tape/magnet when instructed by the CMU installation instructions and a red internal LED will flash briefly on the WSN-4 Series Sensor indicating the unit is awake and attempting to connect to an IONX CMU-EX. 3. Refer to the CMU-EX instructions to complete installation. Section 2:
1. Place the WSN on the Near Field Communication (NFC) reader (supplied by IONX) and follow instructions in the NFC Field Tool User Manual to complete installation. For more information, contact IONX Support Center at 1-800-621-8442, supportcenter@ionxlive.com Label Magnet Magnet/WSN orientation IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 5 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 3. Testing the WSN-4 Series Sensor 1. Reference Manual CMU Installation Manual 303550. 4. Miscellaneous Translations available upon request. Traductions disponibles sur demande. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 6 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 1 WSN-401 Installation Tool Name
(Part No) 3/8 Magnetic Drive Socket
#16 (.177") or 4.5mm Drill Bit 13/64 Drill Bit Required Tools/Materials Description Securing self-drilling screws Drilling pilot holes for self-
tapping screws(Optional)
(should use a stop collar set to no more than 3/8 or 10mm) Drilling clearance holes for
#10 Screws QTY Part No:
Description Supplied Materials 1 W401A0XX WSN-401, Magnetic detector. 1 302211 1 301730 Magnet Spacer, Magnet 1 258464 AAR Compliance Label 4 2 2 2 215215 301731 215217 211694 IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Screw, 10-32x.5, Self Tapping Screw, 10-32x2.25, Button Head
#10 Washer with gasket
#10 Locknut Confidential Revision: C Page 7 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 1 301735 WSN-101 Installation Jig Installing the WSN-401 inside hatch NOTE:
Prior to installation, activate and test the WSN. Choose a mounting location that will not be prone to damage from tools used to access valves and valve plugs, or other routine maintenance. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 8 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 1. Assemble jig with WSN, magnet and magnet spacer as shown on the left. 2. Position jig into hatch ring so magnet spacer is about 1
(25mm) above the top of the ring. 3. Remove adhesive backing on magnet spacer. 4. Fully close hatch lid onto jig. The jig will be slid down to the correct height. 5. Open the hatch lid and the magnet with magnet spacer will be stuck to the lid. 6. Mark and drill holes for the spacer and magnet using the 13/64 Drill Bit. 7. Mount spacer and magnet using the 10-32x2.25 button head screws, sealing washers, and locknuts as shown. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 9 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 8. Mark and drill holes for the Self-Tapping screw using the #16 (.177") or 4.5mm Drill Bit to a depth of 0.5
(12.5mm) 9. Attach WSN using the 10-
32x.5 Self-Tapping screws. 10. Apply the yellow AAR Compliance label on the tank car jacket within 2-5 (50-
125mm) of the WSN where it is clearly visible. Note: Each WSN installed requires the application of one AAR Compliance label. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 10 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 2 WSN-407 Installation Tool Name
(Part No) 5/16 Magnetic Drive Socket
.177 (#16) or 4.5mm Drill Bit Required Tools/Materials Description Securing self-drilling screws Drilling pilot holes (should use a stop collar set to no more than 1/2 or 12mm) Supplied Materials QTY Part No:
Description 1 W407A0XX 1 258464 4 215215 IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering WSN-407, Magnetic Field and Tilt sensor AAR Compliance Label Screw, 10-32x.5, Self Tapping Confidential Revision: C Page 11 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Installing the WSN-407 1. Mounting Dimensions [mm] in. Drill 4 holes .177 (#16) or 4.5mm dia. 2. Attach the WSN with self-tapping screws. 3. Apply the yellow AAR Compliance label on the tank car jacket within 2-5 (50-
125mm) of the WSN where it is clearly visible. Note: Each WSN installed requires the application of one AAR Compliance label. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 12 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 3 WSN-413 Installation Tool Name
(Part No) Required Tools/Materials Description 3/8 Socket wrench Attaching WSN to bracket 7/16 Socket wrench Wire Brush/Grinder Epoxy applicator gun
(McMaster:
74695A71) Applicator tips
(McMaster:
74695A25) Attaching Bracket Assembly to Railcar Prep Surface to epoxy magnet Epoxy applicator gun for applying epoxy. Requires mixing tips below. Applicator tips for mixing and dispensing epoxy QTY Part No:
Description Supplied Materials 1 W413A0XX WSN-413, Magnetic detector. 1 301820 1 258464 Bracket Kit, Empty/Full Sensor AAR Compliance Label 1 301799 Magnet with holder IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 13 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 1 211632 Epoxy Adhesive, Methacrylate IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 14 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Installing the WSN-413 IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 15 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 1. NOTE: INSTALLATION MUST BE PERFORMED ON AN EMPTY CAR. 2. CORRECT SPACING CAN BE DETERMINED BY SETTING UP THE UNIT ON THE OUTSIDE FACE OF THE SIDE FRAME. THE DEFAULT DISTANCE BETWEEN THE TOP OF THE MAGNET AND THE BOTTOM OF THE WSN HOUSING SHOULD BE 0.5" (13MM) HOWEVER SLIGHT ADJUSTMENTS MAY BE NECESSARY ON CERTAIN APPLICATIONS. 3. Apply the yellow AAR Compliance label on the tank car jacket within 2-5 (50-
125mm) of the WSN where it is clearly visible. Note: Each WSN installed requires the application of one AAR Compliance label. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 16 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 4 WSN-414 Installation Tool Name
(Part No) Required Tools/Materials Description Isopropyl Alcohol Preparing tank car surface 120-Grit Wire Brush Attachment
(McMaster: 4914A41) 3/8 Magnetic Drive Socket IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Preparing inner tank car surface Securing self-drilling screws Confidential Revision: C Page 17 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com 3/16 Metal Drill Bit 2 Diameter Bi-metal Hole Saw
(McMaster: 4066A35) Drill Extension Drilling pilot holes
(Optional) Drilling hole in tank car jacket Adding length for wire brush cleaning Supplied Materials QTY Part No:
Description 1 W414A0XX WSN-414, Ext. Temperature Sensor 1 258464 AAR Compliance Label IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 18 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Preparing the Tank Car Jacket 1. Mark the mounting location on the outer tank car jacket, ensuring the area is free of damage or any weld seams and has a suitable curvature to fit the jacket plate assembly. Note: It may be easiest to dry-fit the plate to find the optimal location. 2. Using a suitable 2 diameter hole-saw, drill through the outer jacket. Note: A drill extension may be needed in applications where the insulation is >4 (100mm) thick. 3. Remove any insulation so that a clear path is made from the hole in the outer jacket to the inner jacket surface. 4. Using a suitable wire brush attachment, clean a 2-4 (50-100mm) diameter area on the inner jacket, ensuring rust, grease, and other contaminants are removed. 5. Degrease the abraded inner jacket surface with Isopropyl Alcohol. Note: Solvents other than those listed here may adversely affect the durability and strength of the adhesive bond. 6. On the outer jacket, clean the area surrounding the hole with isopropyl alcohol or suitable solvent. Be sure to remove grease, oil, and any other contaminants. Attaching the Temperature Sensor &
Jacket Plate 1. Peel the adhesive backing from the magnetic sensor. Note: Adhere with ambient and surface temperatures ideally between 70-
100F (21-32C). Do not apply below 50F
(10C) 2. Holding the WSN-414 in one hand and the sensor in the other, feed the magnetic sensor through the hole in the outer jacket and press onto the cleaned inner jacket surface. Note: It may be easiest to test this step before removing the adhesive backing from the magnetic sensor (dry-fit). 3. Pack insulation around the sensor wire, ensuring all voids are filled in. Note: It may be necessary to pack additional insulation in some applications or use expanding foam insulation to replace solid type insulation. Once the magnetic sensor is secured, peel the adhesive backing from the gasket on the underside of the jacket plate. Top of tank car IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 19 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Note: The jacket plate may be square or round depending on the application, both of which follow this instruction set. 4. Carefully press the adhesive plate onto the tank car, centering over the drilled hole. Be sure to 5. orient the assembly as shown to the left in Figure 1. Insert the supplied self-drilling screws in the through-holes on the jacket plate. Be sure to use the tightening sequence shown in the figure to the left in Figure 1. Tighten 40-50 in-lbs (4.5-5.6Nm). 6. Apply the AAR Compliance label on the tank car jacket above the jacket plate (within 2-5 inches or 50-125mm). Note: Each WSN installed requires the application of one AAR Compliance label. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 20 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 5 WSN-415 Installation Tool Name
(Part No) Required Tools/Materials Description Screw Driver 1/8 hex screw driver QTY Part No:
Description Supplied Materials 1 W415A0XX WSN-415 Weld-on Load Cell Assembly AAR Compliance Label 1 258464 IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 21 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Installing the WSN-415 1. Refer to the welding instructions and install the load cell device. Align the WSN at a 90 degree position next to the installed load cell device. 2. Connect the 4 pin connector from the WSN to the Load Cell Sensor. This is a small polarized connector so it should connect in only one direction. 3. Rotate the WSN so it is sitting on top of the 4. load cell sensor. Make sure the slack cable in neatly wrapped around the connector internally. Insert and hand tighten the four screws Inspect the gasket to assure it is sitting flush and there is nothing between the gasket and two mating surfaces. 5. Use the 1/8 hex screwdriver to secure the WSN to the sensor. 6. Apply the AAR Compliance label on the tank car jacket above the jacket plate (within 2-5 inches or 50-125mm). Note: Each WSN installed requires the application of one AAR Compliance label. IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 22 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 6: Compliance Requirements Intrinsic Safety Compliance Conforms To UL STDS 913, 60079-0, & 60079-11 Certified To CSA STD C22.2 # 157, 60079-0, 60079-11, & 25 Electromagnetic Compliance FCC ID 2ADEPWSN4-A applies to WSN devices marked WSN-401, WSN-407, WSN-
408, WSN-413, WSN-414, and WSN-415. FCC WARNING Statement 15.19(a)(3): This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by Amsted Digital Solutions, Inc. could void the users authority to operate the equipment. Numro de certification d'Industrie Canada IC: 12436A-WSN4A s'applique aux appareils WSN marqus WSN-401, WSN-407, WSN-408, WSN-413, WSN-414, and WSN-415. Le prsent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorise aux deux conditions suivantes:
(1) l'appareil ne doit pas produire de brouillage, et
(2) l'utilisateur de l'appareil doit accepter tout brouillage radiolectrique subi, mme si le brouillage est susceptible d'en compromettre le fonctionnement. Industry Canada Certification Number IC: 12436A-WSN4A applies to WSN devices marked WSN-401, WSN-407, WSN-408, WSN-413, WSN-414, and WSN-415. This device complies with Industry Canadas license-exempt RSSs. Operation is subject to the following two conditions:
(1) This device may not cause interference, and
(2) This device must accept any interference, including interference that may cause undesired operation of the device. FVIN: WSN_4_A-1.0 IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 23 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com Appendix 7: Declaration of Conformity IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 24 of 25 IONX Support Center 1-800-621-8442, supportcenter@amsteddigital.com IONX WSN-4 Series Sensor Installation Manual 303506 Revision Date: 30-May-19 Process Owner: Engineering Confidential Revision: C Page 25 of 25