Dwyer Series PMS, Series DPM User manual

Dwyer Series PMS, Series DPM User manual
Bulletin J-25
Particulate Monitoring Systems
DPM
Particulate Monitoring
Systems
DPM Control Units
PMS Sensors
INSTALLATION & OPERATING
MANUAL
Dwyer Instruments, Inc.
102 Indiana Highway 212
P.O. Box 373
Michigan City, IN 46361 USA
Telephone 800-872-9141
www.dwyer-inst.com
Particulate Monitoring Systems
Installation & Operating Manual
I. Technical Support & Return Procedure
Dwyer Instruments, Inc. provides industry leading technical support for all product lines. The
technical support department is staffed with a team of engineering professionals.
Areas of assistance provided by the Technical Support department include:
•
Pre-Installation Site Analysis
•
Product Installation
•
General Operation
•
Application Specific
•
Routine Calibration
•
EPA Compliance
•
Performance Upgrades and Add-On Features
To ensure the best and most efficient technical support please be prepared with the following
information prior to contacting Dwyer Instruments, Inc. If it is determined that the component must be
returned for evaluation/repair, a Return Material Authorization number will be issued. You must
include the RMA number on the packing slip and mark the outside of the shipping container.
•
Company Name
________________________________________
•
Product Model Number
________________________________________
•
Product Serial Number
________________________________________
•
Date of Installation
________________________________________
•
Reason for Return
________________________________________
Dwyer Instruments Technical Support may be reached by:
Phone:
(800) 872-9141
Fax:
(219) 872-9057
E-Mail:
[email protected]
Hours of Operation:
8AM – 5PM Central Standard Time
•
Any control unit or particulate sensor that was exposed to hazardous materials in a process
must be properly cleaned in accordance with OSHA standards and a Material Safety Data
Sheet (MSDS) completed before it is returned to the factory.
•
All shipments returned to the factory must be sent by prepaid transportation.
•
All shipments will be returned F.O.B. factory.
•
Returns will not be accepted without a Return Material Authorization number.
Document No. 209-1025-D
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Particulate Monitoring Systems
Installation & Operating Manual
II. Notifications
This document contains important information necessary for proper operation of the product.
It is strongly urged that all users of the product read this manual in its entirety. All instructions
should be followed properly and any questions that arise should be discussed with Dwyer
Instruments, Inc.
Any use or distribution of this document without the express consent of Dwyer Instruments,
Inc. is strictly prohibited. Any reproduction is prohibited without written permission.
In no event will Dwyer Instruments, Inc. be liable for any mistake, including lost profits, lost
savings, environmental compliance costs or other incidental or consequential damages arising
out of the use or inability to use this manual, even if advised of the possibility of such damages,
or any claim by any other party.
Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
Warning statements help you to:
• Identify a hazard
• Avoid a hazard
• Recognize the consequences
IMPORTANT
Identifies information that is critical for
understanding of the product.
successful application and
Identifies information, sections or statements in this manual that apply to
approved hazardous area systems, regulations or installation.
Document No. 209-1025-D
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Particulate Monitoring Systems
Installation & Operating Manual
III. Approvals and Certifications
CE Conformant
The Control Units and Particulate Sensors conform to the appropriate country standards and
governing regulations listed below:
• EN 61010/1993 “Safety requirements for electrical equipment for measurement, control
and laboratory use.”
• EN 55011/1991 “Limits and methods of measurement of radio interference
characteristics of industrial, scientific and medical equipment”. Class A: Industrial and
commercial.
• EN50082-1/1993 “Electromagnetic compatibility – Generic immunity standard”. Part 1:
Residential, commercial and light industry.
CSA Certified
This Particulate Monitoring system is certified by the Canadian Standards Association (to
US and Canadian Standards) for use in hazardous locations as specified below:
Particulate Sensor:
Intrinsically Safe for Hazardous Locations
PMS-AHZ1 Intrinsically Safe Particulate Sensor in the following areas:
Class I, Division 1, Groups A, B, C, and D
Class II, Division 1, Groups E, F, G
Class III
For use with the Control Units listed below, 70ºC maximum ambient.
Note: There is no temperature rise caused by electrical components. Temperature
code is based only on ambient temperature, (e.g. a 200°C process requires a T3
rating.)
Control Unit:
For use in Ordinary Locations Only
DPM-AHZ1 Control Unit rated 115 Vac/230 Vac, 0.1A or 24Vdc, 0.25A,
70°C, with intrinsically-safe output to Particulate Sensor.
-25ºC to
DPM-AHZ1 Control Unit - Approved for use with PMS-AHZ1
sensors, where the PMS-AHZ1 sensor is the only component located in
the hazardous area.
Document No. 209-1025-D
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IV. Specifications
Ambient Temperature Range
Operating
Pressure Range
Operating
Type
CONTROL UNIT
SPECIFICATION
97–132V~, 47–63Hz
Fuse: 0.032A, Slo-Blo 250V, Type ‘T’
Fuse: 0.050A, Slo-Blo 250V, Type ‘T’ when Self
Check Option is installed
195–264V~, 47–63Hz
Fuse: 0.032A, Slo-Blo 250V, Type ‘T’
Fuse: 0.050A, Slo-Blo 250V, Type ‘T’ when Self
Check Option is installed
22–26VDC
Fuse: 0.250A, 250V, Type ‘T’
6 Watts Max.
picoamperes (pA)
5.0pA – 5000pA
0.5pA – 5000pA
± 5% of Range, std
± 1% of Range, optional
-13°F to +160°F (-25°C to +70°C)
-40°F to +185°F (-40°C to +85°C)
Form A (SPST)
5A @ 240V~ Resistive **Customer must provide a
8A (maximum) fuse in series with relay load.
Isolated
470Ω Max. Loop Impedance
Adjustable Via Keypad
Isolated, Multi-drop, ½ Duplex
19,200 BPS, 8 Data Bits, 1 Stop Bit, No Parity
Painted Cast Aluminum NEMA 4X or optional CSA
Approved Enclosure
PARTICULATE SENSOR
½” NPT Thread
1.5” Quick-Clamp (Mounting ferrule is 1” NPT)
ANSI Flange (2”, 150# is typical)
Others Available
Stainless Steel
With Protective Teflon Layer
Stainless Steel
-40°F to +250°F (-40°C to +120°C)
-40°F to +450°F (-40°C to +232°C)
-40°F to +800°F (-40°C to +426°C)
> 800°F
-40°F to +160°F Maximum (-40°C to +70°C)
Maximum Must be Calculated for each application
Full Vacuum to 10PSI (2.11kg/cm²)
Painted Cast Aluminum
Rating
NEMA 4X (IP 66)
PARAMETER
DETAIL
Input Voltage
115V~
230V~
24VDC
Input Power
Measurement Units
Detection Level/Range
Standard
Optional
Electronic Accuracy
Temperature Range
Relay Outputs
4-20mA Output (Optional)
RS-485 Network (Optional)
Operating
Storage
Type
Rating
Type
Rating
Span
Type
Settings
Enclosure
Type
Mounting
NPT
QC
FL
Other
Materials
Probe
Nipple/Mount
Process Temperature Range
Enclosure
Document No. 209-1025-D
Operating
Page v
NOTE
Selector Switch to 115V
Selector Switch to 230V
No Selector Switch
Optional Model
1 x 10 ⎯ ¹² Amp
Over Full Temp Range
Default: 1000pA LOG
Modbus/RTU Protocol
Other optional
Other optional
Higher Optional
T-Code Ratings for
AHZ1 option only
Higher Optional
Other - Consult Factory
Other - Consult Factory
©2007
Particulate Monitoring Systems
PARAMETER
Type
Temperature Range
Maximum Length
Approximate Particulate
Concentration
Velocity Range
Particle Size Range
Document No. 209-1025-D
Installation & Operating Manual
PARTICULATE SENSOR CABLE
SPECIFICATION
High Quality Coaxial
Operating
-40°F to +392°F (-40°C to +200°C)
300 ft.
DETECTION LEVEL/RESOLUTION AND APPLICATION RANGE
At least 5.0 – 5000 mg/m³
5.0pA
At least 0.002 to 2.0 gr/ft³
Standard
DETAIL
0.5pA
Upgrade
At least 0.5 to 5000 mg/m³
At least 0.0002 to 0.2 gr/ft³
NOTE
Barely Visible to Visible
>5% Opacity
Moderate Dilute Flow
Invisible to Barely
Visible, < 5% Opacity
Light Dilute Flow
150 ft/min. (45.7 m/min.) and Higher
0.3 Micron and higher
If <10.0 Micron, 0.5pA Detection Required
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Particulate Monitoring Systems
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V. Installation Drawings
Drawing Number
Sheets
Description
225-1016-01
2
Particulate Monitor Installation Drawings
225-1014-06
1
Particulate Flow Sensor Installation Drawing, All Mounts
225-1036
1
High Temperature / High Pressure Particulate Flow Sensor
Installation Drawing
Hazardous Area Control Drawing
225-1005
Document No. 209-1025-D
1
Hazardous Area Control Drawing
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TABLE OF CONTENTS
1.
Safety............................................................................................................................................... 2
1.1
Applicable Use.......................................................................................................................... 2
1.2
General ..................................................................................................................................... 2
1.3
Hazardous Area Systems ........................................................................................................... 3
2.
Introduction .................................................................................................................................... 4
3.
Control Unit Installation................................................................................................................. 5
3.1
Location.................................................................................................................................... 5
3.2
Wiring....................................................................................................................................... 5
3.3
Grounding................................................................................................................................. 6
4.
Particulate Sensor Installation........................................................................................................ 7
4.1
Location.................................................................................................................................... 7
4.2
Mounting .................................................................................................................................. 8
4.3
Sensor Temperature Considerations........................................................................................... 9
5.
Particulate Sensor Coaxial Cable Installation.............................................................................. 10
6.
Control Unit Operation................................................................................................................. 12
6.1
User Interface Overview.......................................................................................................... 12
6.2
Menu 1 Setup.......................................................................................................................... 13
6.3
Menu 2 Setup.......................................................................................................................... 14
6.4
Menu 3 Setup.......................................................................................................................... 16
6.5
Long Term Averaging ............................................................................................................. 17
6.6
4-20mA Analog Output Scaling............................................................................................... 18
6.7
Interpreting Particulate Readings for Fabric Filter Applications................................................ 20
6.8
Alarm Levels for Fabric Filter Applications ............................................................................. 22
7.
Manual System Zero Check.......................................................................................................... 23
8.
Automatic Self Checks .................................................................................................................. 26
8.1
Control Unit Hardware Check.................................................................................................. 26
8.2
Control Unit Zero Check ......................................................................................................... 27
8.3
Control Unit Span Check......................................................................................................... 28
8.4
Sensor Cable Check................................................................................................................. 28
8.5
Particulate Sensor Check ......................................................................................................... 28
8.6
Process Running Signal ........................................................................................................... 29
8.7
Monitoring Self Check Status .................................................................................................. 29
8.8
Particulate Alarming During Self Checks................................................................................. 30
8.9
Self check Recording............................................................................................................... 30
9.
Troubleshooting ............................................................................................................................ 31
10. Routine Maintenance .................................................................................................................... 31
11. Spare Parts.................................................................................................................................... 32
12. Appendix ....................................................................................................................................... 33
12.1 Modbus®/RTU RS-485 Networking Protocol .......................................................................... 34
12.2 Ethernet/IP® Networking ........................................................................................................ 37
Document No. 210-1003-M
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Particulate Monitoring Systems
Installation & Operating Manual
1. Safety
1.1
Applicable Use
These particulate monitor systems are not designed for use as a functional safety device and do not
carry a SIL rating. The device must not be used as part of a safety system or as an input signal to a
safety system. These monitors are designed for general process and environmental monitoring.
1.2
General
This apparatus is available with various agency approvals as noted in the approvals section. All
versions of this device have been designed to comply with EN 61010, safety requirements for
electrical equipment for measurement, control and laboratory use, and are supplied in a safe condition.
Before beginning an installation the following safety precautions and all precautions noted listed
throughout this manual and in the installation drawings must be followed.
AREA CLASSIFICATION
•
Before installing any device confirm area classification requirements. Do
not install any device that is not tagged as suitable for the required area
classification.
PROCESS AND AMBIENT CONDITIONS
•
Before installing any device, confirm ambient temperature, process
temperature and process pressure requirements. Do not install any device
that is not tagged as suitable for the required temperatures and pressures.
Confirm compatibility of the wetted and non-wetted materials.
INSTALLATION PERSONNEL AND SERVICE
•
Only appropriately licensed and trained professionals should perform the
mechanical and electrical installation.
•
This device does not contain field serviceable components other than the
line fuse. Only factory personnel can perform service on this equipment.
•
For operator safety and to prevent ignition of flammable or combustible
atmospheres always disconnect power before servicing.
GROUNDING AND FUSING
•
Before turning on the instrument, you must connect the protective earth
terminal of the instrument to a proper earth ground. Grounding to the
neutral conductor of a single-phase circuit is not sufficient protection.
•
Only fuses with the required current, voltage and specified type should be
used. Do not use repaired fuses or short-circuited fuse holders.
REGULATORY CODES
•
Document No. 210-1003-M
Installation and operation must adhere to all national and local codes.
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Particulate Monitoring Systems
1.3
Installation & Operating Manual
Hazardous Area Systems
Systems approved for use in hazardous areas include nameplates indicating that they are suitable for
installation in hazardous areas. The nameplate lists allowable hazardous areas and T code ratings as
well as approval agency markings. Do not install any device that is not tagged as suitable for the
area classification.
Sections or statements in this manual that apply to approved hazardous area systems or installations
are designated with the following symbol. Designation for use in hazardous areas does not make the
system suitable for use as a functional safety device.
EXPLOSION HAZARD
Document No. 210-1003-M
•
Hazardous area control drawing 225-1005 must be followed for proper
installation.
•
Installation must be in accordance with ANSI/ISA RP12.6 and National
Electric Code ANSI/NFPA 70, Article 504
•
Substitution of components may impair intrinsic safety.
•
Do not connect or disconnect components unless power has been
disconnected.
•
Designation for use in hazardous areas does not make the system
suitable for use as a functional safety device.
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Particulate Monitoring Systems
Installation & Operating Manual
2. Introduction
A Particulate Monitoring System consists of a control unit, a particulate sensor and a sensor coaxial
cable. Applications include continuous emissions monitoring, baghouse filter leak detection and
process particulate flow monitoring. Types of particulate include both solid particulates (dusts,
powders, granulars and pellets) and liquid particulates (mists). Various control unit models and
sensors are provided to match the application and process monitoring needs.
Principle of Operation
Particulate Monitoring Systems employ a highly reliable technology based on induction. A sensor
probe is mounted in an airflow stream such as a pipe, duct or stack (for small tubing an inline nonintrusive ring sensor is employed). As particulate flows near and over the sensing element, minute
electrical currents are induced in the sensor and transferred to the control unit by a coaxial cable. A
microprocessor filters and processes the signal into a normalized, absolute output that is linear to the
mass concentration of particulate.
_
IMPORTANT
MASS CORRELATION
It is important to note that the above relation between instrument units (pA) and
actual mass (mg/m3 or gr/cf) is just an approximate guide for selecting the
appropriate model and range and for providing a general indication of the typical
particulate levels monitored. For a true correlation between (pA) and actual
mass (mg/m3 or gr/cf), a gravimetric correlation such as an isokinetic sample
must be performed for each application and a recommended model and
detection level must be ordered. It is also important to note that the accuracy of
such correlations is application dependent and produces the best results with
consistent particulate and process conditions. The user must follow proper
procedures and must understand the typical accuracy of such correlation
techniques. Consult factory for details.
Control Unit
The control unit (i.e. electronics) is housed in a rugged cast aluminum enclosure. An LCD displays
particulate levels in bar-graph and digital forms. A lockable membrane keypad is provided for setup
and adjustment. An optional self check sub system is available to automatically verify calibration and
operation of the control unit, sensor and cable. Various relay, analog inputs and outputs, as well as
serial communications are available in the control unit.
Particulate Sensor
The particulate sensor is very rugged and virtually maintenance-free. The sensor is passive with no
active circuits for high reliability and durability. It does not require special alignment and is not
affected by normal vibration.
Coaxial Cable for Particulate Sensor
The cable that connects the particulate sensor to the control unit is a high-quality coaxial cable
specifically designed for the system. Maximum length is 300 ft (91m). Do not use substitute cable.
Document No. 210-1003-M
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Particulate Monitoring Systems
Installation & Operating Manual
3. Control Unit Installation
3.1
Location
The following factors should be considered when determining the control unit location:
ƒ
Locate at a position that is convenient for setup and operation
ƒ
Mount at eye level
ƒ
Mount to a flat surface in a vertical orientation
ƒ
Do not mount to surfaces with excessive heat or vibration
INSTALLATION PERSONNEL
•
Only appropriately licensed professionals should install this product.
•
For operator safety and to prevent ignition of flammable or combustible
atmospheres always disconnect power before servicing.
CONTROL UNIT LOCATION
•
The control unit may only be located in ordinary locations (non-hazardous
safe areas).
•
Do not locate the control unit in a hazardous area unless it is inside an
appropriately rated explosion-proof or purged enclosure and supplied as
part of an approved hazardous area system with approved control unit and
approved sensor assembly.
•
Do not locate the control unit in or near sources of very high electrical noise
such as a Variable Frequency Drive (VFD) or Motor Control Center. Locate
the control unit at least 10 feet from these sources and, if possible, power
the control unit from a separate power source. If power is supplied from the
same branch circuit or a circuit containing electrical noise, install a quality
line filter such as an Islatrol IC+102.
Mounting: Mounting holes are integrated into the enclosure base. Mounting hardware should be
capable of supporting five times the control unit weight. Refer installation drawings for dimensions.
3.2
Wiring
An appropriately licensed electrician must perform all electrical connections.
CONTROL UNIT WIRING
Document No. 210-1003-M
•
All wiring must be rated 250V minimum.
•
The control unit must be mounted within sight of an appropriate electrical
disconnect (on/off switch) to ensure safety during installation and
maintenance.
•
The coaxial cable must be in conduit that is separate from all other circuits.
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Particulate Monitoring Systems
Installation & Operating Manual
There are connections inside the control unit for the sensor coaxial cable, the power supply, relay
contacts and optional 4-20mA or RS-485 outputs. Refer to the installation drawings.
Conduit openings are provided in the bottom of the enclosure to route wiring into the enclosure.
Never drill new conduit openings in the side or top of the enclosure as a bad conduit seal may allow
water to enter the enclosure.
3.3
Grounding
Proper grounding of the control unit is essential to ensure reliable operation and operator safety.
When used as part of an approved hazardous area system two separate ground connections are
required, protective ground and intrinsic safety ground. It is not sufficient to use a single ground
connection and jumper the protective and intrinsic safety grounds inside the control unit enclosure.
CONTROL UNIT GROUNDING
Document No. 210-1003-M
•
Protective earth ground must be connected to terminal #1.
•
The enclosure cover must be bonded to the enclosure base with the supplied
ground bonding wire – do not remove.
•
When used as part of an approved hazardous area system: Intrinsic safety
ground must be connected to terminal #2 and must be less than 1 ohm with
respect to earth ground. Refer to control drawing 225-1005.
•
When used as part of an approved hazardous area system: Intrinsic safety
ground must utilize a grounding electrode independent of the protective
earth ground.
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Particulate Monitoring Systems
Installation & Operating Manual
4. Particulate Sensor Installation
4.1
Location
The following factors should be considered when determining the sensor location:
ƒ
Area Classification
ƒ
Flow conditions
ƒ
Electrical (Faraday) shielding
ƒ
Atmospheric shielding (in the case of ducts and stacks open to atmosphere)
ƒ
Access for installation and service
SENSOR LOCATION
•
Before installing the sensor, confirm area classification requirements. Do
not install any device that is not tagged suitable for the required area
classification.
•
Before installing the particulate sensor, confirm ambient temperature,
process temperature and process pressure requirements. Do not install any
device that is not tagged as suitable for the required temperatures or
pressures. Confirm compatibility of wetted and non-wetted materials.
•
For hazardous areas, a maximum ambient temperature of the particulate
sensor enclosure must not be exceeded. Refer to the Temperature
Considerations section for full details.
It is essential for the pipe/duct to provide an electrical (Faraday) shield for the sensor. It is therefore
required that the pipe, duct or stack is metal and earth grounded (small inline tubing sensors provide
their own section of metal pipe which also must be grounded). Consult the factory when insertion
probe style sensors are to be installed in non-conductive pipes, ducts such as plastic or fiberglass.
The particulate sensor must be installed in a position where the flow is reasonably laminar and the
particulate is evenly distributed. The ideal position is where the pipe/duct is straight and free of items
such as valves, dampers or other flow obstructions for a length of 4 diameters or longer. Horizontal or
vertical sections are acceptable. For basic flow/no flow detection it is not necessary to select a
location with a long straight section if access has to be sacrificed dramatically. For trending and
measurement the need for a straight section and laminar flow increases. The particulate sensor should
be positioned with approximately two thirds of the straight section upstream of the sensor and one
third downstream. The particulate sensor should be located in the center of the pipe/duct. If the
pipe/ducting is square it should be located in the center of one of the sides. In either case, be sure the
position is such that the tip of the sensor reaches the midpoint or beyond. Always use good
engineering sense and be sure the sensor will interact with a reasonable representation of the flow.
For emissions detection applications such as baghouses or cartridge collectors, good locations are
generally found upstream of the blower. The particulate sensor can be located downstream of the
blower but not too close to the stack outlet. There must be sufficient duct downstream of the sensor to
provide adequate electrical and atmospheric shielding. The sensor should be located upstream of any
sampling ports by at least two feet. It is not necessary that the sensor be in the same section of the
duct/stack as the sampling ports. Particulate sampling ports require fully-developed laminar flow and
longer straight sections.
Document No. 210-1003-M
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Particulate Monitoring Systems
Installation & Operating Manual
Extreme vibration should be avoided.
_
IMPORTANT
4.2
ATMOSPHERIC AND ELECTRICAL SHIELDING OF SENSOR
•
It is essential for the pipe/duct to provide an electrical (Faraday) shield for
the sensor. The pipe/duct or stack should be metal with a high quality earth
ground. Consult the factory for non-conductive pipes/ducts such as plastic
or fiberglass. (Small in-line sensors for small tubing provide their own
section of metal pipe, which also must be grounded).
•
When the sensor is placed in a stack/duct choose a location away from
atmosphere so wind driven atmospheric particulate or rain does not flow
over the sensor and so external electrical noise cannot affect operation.
•
Do not place the sensor where the pipe/duct is corroded or cracked which
may allow water droplets to create signals as they flow by.
Mounting
The following types of process mounts are available for the standard probe style sensors:
NPT, Quick-Clamp and ANSI flange.
Inline sensors for small tubing are supplied with swage lock or other tube connections to mount inline
with metal or plastic tubing.
Installation drawings of each mounting type can be found in the appendix.
HAZARDOUS AREA SENSOR GROUNDING
Document No. 210-1003-M
•
For hazardous area applications an external sensor earth ground cable is
required to maintain sensor grounding during installation and maintenance.
•
The ground cable must remain attached when the sensor is temporarily
removed from the process – do not disconnect the ground cable.
•
Leave sufficient ground cable service loop for easy removal of the sensor
from the process.
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Particulate Monitoring Systems
4.3
Installation & Operating Manual
Sensor Temperature Considerations
The sensor may be ordered with one of three process temperature ranges:
1.
-40ºF to 250ºF (-40ºC to 121ºC)
2.
-40ºF to 450ºF (-40ºC to 232ºC)
3.
-40ºF to 800ºF (-40ºC to 426ºC)
4.
Consult Factory for Temperatures >800°F
Note: For the process temperatures in the range of 233ºC - 426ºC, a high temp probe must be used.
The maximum allowable ambient temperature at sensor housing is 70ºC.
Table: T Code Rating for Sensor
Process Temperature Does Not Exceed
Maximum Ambient
75ºC (167ºF)
125ºC (257ºF)
225ºC (437ºF)
325ºC (617ºF)
426ºC (800ºF)
70ºC (160ºF)
T6
T4
T2C
T1*
T1*
Document No. 210-1003-M
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Particulate Monitoring Systems
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5. Particulate Sensor Coaxial Cable Installation
Connection: Prior to making coaxial cable connections review the following routing instructions.
IMPORTANT
_
PARTICULATE SENSOR COAXIAL CABLE ROUTING
•
The sensor cable must be installed in conduit that is separate from all other
wiring.
•
The cable should be routed from the particulate sensor to the control unit in
a path that avoids high vibration, heat over 394°F (200°C) and any strong
magnetic or electrical fields.
•
The cable should be located at least 18 in (46 cm) away from any power
lines (conduit), motors, frequency drives and other sources of electrical
interference throughout its entire path.
•
The cable should be installed in metallic conduit. At the process end, use a
section of shielded flex conduit that is 1 to 2 times the probe length to serve
as a service loop.
The coaxial cable is connected to the control unit by a coax connector and is connected to the sensor
by two ring terminals. The connectors are normally supplied pre-assembled to the cable.
Once the cable has been routed, insert the coax connector into the control unit enclosure leaving a
very small service loop as specified in the installation drawing shown in the appendix. A larger
service loop should be used at the sensor end, typically 1 to 2 times the sensor length. Any small
amount of extra cable length should be pulled into the nearest junction box and NOT left in the sensor
housing or in the control unit enclosure. If there is a significant amount of extra cable (many feet), the
cable should be shortened at the sensor end and the sensor end connectors should be re-assembled
using factory-supplied connectors and instructions.
IMPORTANT
_
COAXIAL CABLE INSIDE THE CONTROL UNIT
•
A ferrite suppressor is located on the sensor coaxial cable near the coax
connector and must remain inside the control unit enclosure.
•
The black cable insulation must extend a minimum of 6 in (15 cm) into the
coax cable conduit.
•
Do not leave any excess cable in the control unit or sensor housing.
Inside the particulate sensor enclosure, attach the coax cable as indicated in the sensor drawing. When
connecting the braided shield, ensure it does not touch the surge voltage protection assembly. Do not
leave excess cable inside the sensor housing.
Document No. 210-1003-M
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Particulate Monitoring Systems
Installation & Operating Manual
Sensor Test Port (Non-Hazardous Areas Only)
Location: A test port should be installed in a negative pressure location. It must be located upstream
of the sensor so particulate can flow very near and around the sensor. It should be located at least 3 ft
(1 m) upstream of the sensor and it should be located on the same side of the duct as the sensor so
particles can pass very near and around the sensor. If possible locate the test port at ground level.
Mounting: The test port is either screwed into a 1/8 inch NPT threaded hole, or welded in position.
(Note: A foot or so of tubing can be connected to the nipple to make it easy to draw particles out of a
container. Only a pinch of particulate at a time is needed for a response check.)
_
IMPORTANT
TEST PORT INSTALLATION
•
Document No. 210-1003-M
Installation of a sensor test port enables checking the response to an actual
increase in particulate.
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©2007
Particulate Monitoring Systems
Installation & Operating Manual
6. Control Unit Operation
6.1
User Interface Overview
The following drawing shows the user interface consisting of a four-button keypad and an LCD
display. The LCD display has a scalable analog bar graph combined with a digital readout for ease in
interpreting the dynamic readings, which are typical with particulate flow.
Control Unit
The control unit has two alarm relays which are individually activated when the reading continuously
exceeds the alarm setpoint for the amount of time delay specified. Each is an SPST (FORM A) relay
contact output.
Alarm logic may be set to Normal or Fail-safe mode. In Normal mode, the alarm relay contact is open
under normal conditions and closes when the associated alarm is active. In Fail-safe mode, the alarm
relay contact is closed under normal conditions and opens when the associated alarm is active, or
when power to the control unit is removed.
When the reading exceeds the alarm setpoint, the alarm delay timer is started. As long as the reading
remains above the alarm setpoint, the alarm delay timer will continue timing. If the reading drops
below the alarm setpoint before the alarm delay timer expires, the alarm delay timer is reset. If the
reading remains above the alarm setpoint and the alarm delay timer expires, an alarm is activated and
the associated alarm relay contact will close (Normal logic) or open (Fail-safe logic).
If an alarm is activated and the reading drops below the alarm setpoint, the alarm is cleared and the
alarm delay timer is reset. As described above, alarms will clear automatically and no operator
acknowledgment is required.
Control units designed for powder flow applications include the ability to define a LOW alarm level
that will activate when the particulate reading falls BELOW the setpoint. See Menu 1 Setup details.
Document No. 210-1003-M
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Particulate Monitoring Systems
6.2
Installation & Operating Manual
Menu 1 Setup
Alarm setpoints are accessed through Menu 1 setup. To enter Menu 1, press the SETUP key.
Setpoints may be modified by pressing the UP and DOWN arrow keys. Values are saved by pressing
the ENTER key. To discard any changes made and return to the main screen, press the
SETUP/ESCAPE key. Refer to the Menu 1 setup diagram below for menu navigation and allowable
setpoint ranges. Features designated with an asterisk (*) are optional. Operation of optional features is
dependant upon model and options selected at the time of order. The following setup menus are based
on firmware version 2.27 or higher.
From the main screen, press the SETUP key to enter the Menu 1 setup screen.
Use the UP/DOWN arrow keys to adjust settings to the desired values. Press the
ENTER key when finished to save a value and proceed to next menu item.
Press the SETUP/ESCAPE key to return to the main screen without saving the
current parameter’s value.
Document No. 210-1003-M
Menu Item
Range
Alarm #1
Relay #1
Setpoint
0-5000
pA
The alarm setpoint is compared to the process
reading to determine alarm status. Relay #1 will
close when alarm #1 is active and open when
alarm #1 is cleared.
Alarm #1
Relay #1
Delay
1-600
Sec
Number of seconds the reading must exceed the
alarm setpoint before alarm relay #1 contact will
close.
* Alarm #1
Relay #1
Logic
HI/LO
Select the logic for the alarm. HI activates when
the reading is above the setpoint. LO activates
when the reading is below the setpoint.
Alarm #2
Relay #2
Setpoint
0-5000
pA
The alarm setpoint is compared to the process
reading to determine alarm status. Relay #2 will
close when alarm #2 is active and open when
alarm #2 is cleared.
Alarm #2
Relay #2
Delay
1-600
Sec
Number of seconds the reading must exceed the
alarm setpoint before alarm relay #2 contact will
close.
* Alarm #2
Relay #2
Logic
HI/LO
Select the logic for the alarm. HI activates when
the reading is above the setpoint. LO activates
when the reading is below the setpoint.
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Definition
©2007
Particulate Monitoring Systems
6.3
Installation & Operating Manual
Menu 2 Setup
Navigation within Menu 2 is similar to that described in Menu 1. Features designated with an asterisk
(*) are optional. Operation of optional features is dependant upon model and options selected at the
time of order. The following setup menus are based on firmware version 2.27 or higher.
Press the SETUP and ENTER keys at the same time from any main screen to enter
the Menu 2 setup screen. Use the UP/DOWN arrow keys to adjust the setting to the
desired value. Press the ENTER key to save the value and proceed to the next setup
screen. Press the SETUP/ESCAPE key to return to the main screen without saving the
current parameter’s value.
Menu
Item
Bar
Graph
Span
Document No. 210-1003-M
Range
Automatic
Automatic
100,000
10,000
1,000
100.0
10,000
1,000
100.0
10.0
1.0
Linear
Log
Log
Log
Log
Log
Linear
Linear
Linear
Linear
Linear
Definition
Allows the user to configure the full-scale
span of the bar graph readout. The user
may select a fixed scale, or a auto-ranging
scale where the unit will select it’s own scale
automatically. The user can select between
a LINEAR or LOGARITHMIC scale. (Log
scaling is recommended for processes with
dynamic, spiking readings such as a
baghouse or cartridge type dust collector.)
Lock
Keypad
No/Yes
Locks the keypad to prevent unauthorized
modifications. Once locked, alarm levels
cannot be viewed or modified until the
keypad is unlocked. To ulock, enter Menu 2
and set the lock keypad parameter to NO.
Reset
Defaults
No/Yes
Resets all alarm set points and useradjustable parameters to their factory default
values by selecting YES
* 4-20mA
Minimum
Scale
0.0
Linear
0.1 – 10.0 Log
Sets the 4mA value of the 4-20mA output.
Entering “0.0” defines Linear scale. A value
other than “0.0” defines logarithmic scale.
* 4-20mA
Output
Span
0 – 5,000 Linear
1 – 900,000 Log
Sets the 20mA value of the 4-20mA output.
Linear span can be set to any value.
Logarithmic span will also determine the
number of decades. Example:
Linear output: Min Scale=0.0, Output
Span=1,000.
3-decade logarithmic output: Min Scale=1.0,
Output Span=1,000.
* Network
Address
1 - 32
Modbus®RTU slave address for the RS-485
serial network. Each device must have a
unique address.
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Particulate Monitoring Systems
Document No. 210-1003-M
Installation & Operating Manual
Fail-safe
Relay 1
No/Yes
When set to “Yes”, inverts the alarm relay
logic. Relay is ON when NO alarm condition
exists and is OFF when there IS an alarm
condition. Relay is OFF when power is
removed from the control unit.
Fail-safe
Relay 2
No/Yes
When set to “Yes”, inverts the alarm relay
logic. Relay is ON when NO alarm condition
exists and is OFF when there IS an alarm
condition. Relay is OFF when power is
removed from the control unit.
Process
Run
Relay
Enable
No/Yes
When set to “Yes”, enables use of the
process run relay input channel. When set
to “No”, disables use of this input. Refer to
Automated Self Checks section of the
manual for details on use of this relay input.
* Perform
Zero
Check
No/Yes
When set to “Yes”, triggers an automatic
zero check. Refer to Automatic Self Checks
section of manual for full details.
* Perform
Span
Check
No/Yes
When set to “Yes”, triggers an automatic
span check. Refer to Automatic Self Checks
section of manual for full details.
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Particulate Monitoring Systems
6.4
Installation & Operating Manual
Menu 3 Setup
Navigation within Menu 3 is similar to that described in Menu’s 1 and 2. Features designated with an
asterisk (*) are optional. Operation of optional features is dependant upon model and options selected
at the time of order. The following setup menus are based on firmware version 2.27 or higher.
Press the UP and DOWN keys at the same time from the main screen to enter the Menu 3 setup
screen. Use the UP/DOWN arrow keys to adjust a setting to the desired value. Press the ENTER
key to save the value and proceed to the next screen. Press the SETUP/ESCAPE key to return to
the main screen without saving the current parameter’s value.
Document No. 210-1003-M
Menu Item
Range
Definition
Signal
Filter
Frequency
0.033 – 2.0
Hz
This parameter controls the low-pass filtering of the input
signal. Setting the frequency lower gives a more stable
output reading. Setting the frequency higher gives a more
dynamic output reading. Signal filtering is applied to the
numeric readout only unless bar graph/4-20mA filtering is
ON (see setting below).
* Units of
Measure
1111 pA
2222 mg
This parameter sets the displayed and output units of
measure to be either pA or mg/m3. Conversion to mg/m3
first requires correlation testing and instrument scaling.
AutoRange
Delay
1 – 30
Sec
This parameter controls how long the bar graph readout
must be at either extreme before it automatically switches
ranges. If the bar graph is switching ranges too often, the
auto-range delay should be increased.
* Peak Hold
Time
0 – 60
Sec
This parameter sets the amount of time a rapidly
occurring peak reading is displayed. Peak Hold is used
for processes that are very dynamic with spiking
readings.
* Bar Graph
&
4-20mA
Output
Filtering
Yes/No
This parameter enables or disables filtering of the bar
graph and the optional 4-20mA output. The filtering
applied is the Signal Filter Frequency parameter listed
above. Filtering is enabled by selecting YES and disabled
by selecting NO.
*
Correlation
Values
MINIMUM
and
MAXIMUM
(EM 70)
0 – 5000
These parameters are used to re-scale the output from
pA to mg/m3. Raw min/max values (pA1 and pA2) are
entered and equivalent Scaled min/max values (pA3 and
pA4) are entered. The control unit will convert the Raw
values to Scaled values automatically. To remove all
scaling, set Raw min=Scaled min and Raw max=Scaled
max. Example: 0-5000pA = 0-4000mg/m3
pA1=0, pa2=5000, mg3=0, mg4=4000
pA1=0
pA2=5000
pA3=0
pA4=5000
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Particulate Monitoring Systems
6.5
Installation & Operating Manual
Long Term Averaging
The long term averaging function provides a rolling average of the real-time readings over time.
Press the ENTER key to toggle between the Real-Time display and the Average display.
Main
Screen
Units
Shown
Description
Real-Time
Display
pA
Displays the real-time reading. Before display, the real-time
reading is processed through a low-pass input signal filter
which smoothes the reading. See the low-pass “Signal Filter
Frequency” setup in the Menu 3 setup section.
Average
Display
ApA
Displays a selectable rolling time average of the real-time
reading. The average period (in minutes) is adjustable
through the average setup screen. The word “AVG” is quickly
shown in place of the readout once every five seconds,
indicating that the displayed and output reading is an
average.
Averaging setpoints are accessed through averaging setup screen. To enter the averaging setup screen,
press the SETUP key while viewing the MAIN AVERAGE screen. Navigation within the setup
menu is similar to that described in the previous setup screens.
Press the SETUP key from the MAIN AVERAGE screen to enter the
AVERAGE setup screen. Use the UP/DOWN arrow keys to adjust
settings to the desired values. Press the ENTER key to save a value and
proceed to next setup screen. Press the SETUP/ESCAPE key to return
to the main average screen without saving the current parameter’s value.
Document No. 210-1003-M
Menu Item
Range
Average
Period
0-360
Min
Clear
Average
YES/NO
Page 17
Definition
Number of minutes the real-time
reading is averaged to compute the
average reading.
When YES is selected and the enter
key is pressed the averaging is cleared
and the average reading is initialized
to 0.
©2007
Particulate Monitoring Systems
6.6
Installation & Operating Manual
4-20mA Analog Output Scaling
Particulate levels may be transmitted to external devices with the 4-20mA analog output. Typical
applications include remote monitoring of particulate levels with a PLC, chart recorder or panel
meter. The 4-20mA output is transmitted as linear or multi-decade logarithmic output.
Two parameters determine the type of output signal. The “4-20mA Minimum Scale” parameter
determines the pA equivalent of the 4mA output. Setting this parameter to “0.0” enables the Linear
scale. A value other than “0.0” initiates Logarithmic scale. The “4-20mA Output Span” parameter
determines the pA equivalent of the 20 mA output.
The 4-20mA analog output represents the linear or logarithmic equivalent of the “pA” particulate
levels. Once the analog output has been transmitted to the PLC or chart recorder, it is recommended to
convert the 4-20mA signal back into pA to assist in data interpretation, alarm level determination and
historical data comparison. This can be of particular importance for EPA regulatory applications. The
following two examples show the formulas used to convert the 4-20mA signal into pA.
4-20mA Linear Output
Linear output is selected when the “4-20mA Output Minimum Scale” is set to “0.0” pA. To convert
the 4-20mA output signal back to pA, use the following formula:
pA = ((4-20mA Output Span) * (mA - 4)) / 16
Example:
Where:
4-20mA Minimum Scale = 0.0 and
4-20mA Output Span = 1000pA (from Menu #2)
4-20mA Output
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Document No. 210-1003-M
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pA
0.0
62.5
125.0
187.5
250.0
312.5
375.0
437.5
500.0
562.5
625.0
687.5
750.0
812.5
875.0
937.5
1000.0
©2007
Particulate Monitoring Systems
Installation & Operating Manual
4-20mA Logarithmic Output
To convert the 4-20mA logarithmic output back to pA, use the following formula:
1.
Compute the number of output decades:
Number_Of_Decades =Log [(4-20mA Output Span)/(4-20mA Minimum_Scale)]
2.
Scale mA input to proper log(10) argument:
Y = Number_Of_Decades * (mA – 4.00) / 16
3.
Convert log(10) argument to pA:
pA = 10^(Y) * (4-20mA Minimum_Scale)
Example #1: See Menu #2 for details.
Where: 4-20mA Minimum Scale = 0.1pA
4-20mA Output Span = 1000pA
Number_Of_Decades = Log (1000 / 0.1) = 4
4-20mA Output
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Document No. 210-1003-M
Y
0
0.25
0.5
0.75
1
1.25
1.5
1.75
2
2.25
2.5
2.75
3
3.25
3.5
3.75
4
Page 19
pA
0.1
0.2
0.3
0.6
1.0
1.8
3.2
5.6
10.0
17.8
31.6
56.2
100.0
177.8
316.2
562.3
1000.0
©2007
Particulate Monitoring Systems
Installation & Operating Manual
Example #2: See Menu #2 for details.
Where: 4-20mA Output Minimum Scale = 0.5pA
4-20mA Output Span = 500pA
Number_Of_Decades = Log (500 / 0.5) = 3
4-20mA Output
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
6.7
Y
0.00
0.19
0.38
0.56
0.75
0.94
1.13
1.31
1.50
1.69
1.88
2.06
2.25
2.44
2.63
2.81
3.00
pA
0.5
0.8
1.2
1.8
2.8
4.3
6.7
10.3
15.8
24.3
37.5
57.7
88.9
136.9
210.8
324.7
500.0
Interpreting Particulate Readings for Fabric Filter Applications
Particulate flow is very dynamic in nature, thus the output signal is also usually very dynamic. This is
more often the case with fabric filter and dust collection exhaust monitoring applications where filter
emissions and filter cleaning systems can cause wide ranging variations in the particulate levels.
When monitoring downstream of fabric filter, it is often possible for the difference between baseline
readings and peak readings following cleaning cycles, to vary by a factor of 10 or even 100. This is
the reason for the logarithmic output (linear output is also easily selected using the keypad).
The logarithmic scale provides the ability to simultaneously monitor and resolve the baseline and
peak readings. It is not uncommon to have baseline readings of less than 10pA while at the same time
peak readings may be over a hundred or more.
Particulate levels listed below are typical for new or well maintained bag or cartridge filter dust
collection system. Many factors, other than generic bag wear may contribute to high particulate levels
including but not limited to: Improper filter installation, bad tube sheet seals, improper filter media
for process conditions, high differential pressure or a lack of a filter cake buildup.
Document No. 210-1003-M
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Particulate Monitoring Systems
IMPORTANT
Installation & Operating Manual
PARTICULATE READING GUIDE FOR FABRIC FILTERS
•
The guide below is only an approximate guide for modern, highly-efficient baghouses
•
With larger or older baghouses, readings can be significantly higher than the ranges shown below
•
Shaker and reverse air baghouses will have higher peak readings as compared to pulse jet
•
Readings tend to be higher when new filters are installed and a filter cake has yet to form
•
With small cartridge filters, the readings tend to be at the lower end of the ranges
•
Readings tend to also be lower with highly-efficient filter media such as Gore-Tex® fabric (GoreTex is a registered trademark of W.L. Gore & Associates.)
•
Typical Readings and Guide for New Efficient Fabric Filters
AVERAGE
BASELINE READINGS
1 – 10 pA
10 – 100 pA
100 – 1000pA
_
IMPORTANT
PEAK READINGS
(after cleaning cycle)
Less than 50pA
Less than 500pA
Greater than 500pA
FILTER CONDITION
No significant emissions
Onset of emissions
Significant emissions present
ALARM LEVELS FOR EPA COMPLIANT LEAK DETECTION
•
Alarm levels for EPA compliant leak detection such as MACT regulations should initially be set as
low as possible until sufficient trend data has been logged and all considerations have been made.
•
Do not increase the alarm levels without proper justification.
•
Documentation of properly determined alarm levels is recommended as well as locking out alarm
set point adjustment except to authorized personnel.
•
Consult factory for alarm set point assistance and or FilterWare Visualization and EPA Compliance
Software for advanced alarming and alarm record keeping.
Document No. 210-1003-M
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Particulate Monitoring Systems
6.8
Installation & Operating Manual
Alarm Levels for Fabric Filter Applications
For fabric filter applications it is recommended to set two alarm levels either using the internal alarms
and or using the optional 4-20mA output signal that is sent back to a PLC or other recording system.
One alarm should be set based on the average base line reading and another alarm should set based on
the peak readings following cleaning cycles.
Normally, Alarm #1 is used for detecting sustained increases in the base line reading. For example a
baghouse that has new, highly-efficient filters may have an average baseline reading of 10-20pA. It
would then be recommend to set the baseline alarm at 30-50pA with an alarm delay time that was
long enough so that cleaning cycle peaks did not activate the baseline alarm. Each application can be
different (for example much higher readings are possible with larger, older baghouses) and each plant
may have different operating demands in terms of how sensitive the alarms should be set. It is,
therefore, recommended to initially set the alarm as low as possible and to trend and data log the
readings over time before finalizing the settings. Correlations to stack test data can also be
incorporated to correlate the output to actual mass concentration to set more quantitative alarms.
Normally, Alarm #2 is set to detect changes in the peak readings caused by the filter cleaning cycles.
Recall that as filters just begin to tear or become porous, the momentary puffs of particulate emissions
that normally occur just after a cleaning cycle will increase in peak height and duration (peak width).
Essentially the cleaning cycle amplifies the existence of small tears. Thus, setting an alarm to detect
changes in the peak emissions is often referred to as a Pre-Visible Alarm as it is the best, and most
reliable, approach to detecting emissions before become visible. When a sustained increase in the
baseline level occurs, particulate emissions will likely be visible and the filters should be changed
immediately. Where as, when only the peak emissions have increased, emission will likely not be
visible and there likely would be time to schedule changing the filters (i.e. early warning).
Telephone or on-site assistance is available to provide suggestions in setting alarm levels.
Document No. 210-1003-M
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Particulate Monitoring Systems
Installation & Operating Manual
7. Manual System Zero Check
The System Zero Check is used at installation to confirm proper installation and for troubleshooting.
This check is mostly for control units that are not equipped with the optional self check subsystem.
SAFETY
•
Always disconnect power to the control unit before making any wiring
changes at either the control unit or sensor as well as when making any
mounting changes or replacing any component.
•
Do not remove the sensor (even when power is disconnected) from a
running process if it will in any way compromise personnel or plant safety.
•
All regulatory and plant safety procedures must be followed at all times
while performing any equipment check or maintenance.
•
For hazardous area sensors, do not disconnect the external earth ground
strap.
•
Do not perform any procedure if it will in any way compromise hazardous
area procedures.
SYSTEM ZERO CHECK
1.
Shut the process off, stopping flow completely, including all airflow not just
particulate flow. The slightest amount of flowing particles can create a
signal. If process flow cannot be stopped, the particulate sensor can be
removed from the process and installed in a grounded test pipe to create a
shielded, no flow condition.
2.
Let the system stabilize for 2-3 minutes.
3.
Read the display. It should be below the control units specified minimum
detection level. If the system passes this check then it is assured that there
are no false signals entering the system.
If the system zero check is not successful, each component of the system should
be checked individually, in the following order:
Document No. 210-1003-M
1.
Control Unit Zero Check
2.
Coaxial Cable Zero Check
3.
Sensor Zero Check
Page 23
©2007
Particulate Monitoring Systems
Installation & Operating Manual
CONTROL UNIT ZERO CHECK
1.
Disconnect power to the control unit.
2.
Open the enclosure cover and unscrew the coaxial cable connector from the
control unit. Leave the connector inside the control unit enclosure. Make
sure the connector does not slip down into the conduit.
3.
Close the control unit enclosure cover.
4.
Re-apply power to the control unit and allow the reading to stabilize for 1-2
minutes.
5.
Read the display. It should be below the control units specified minimum
detection level. If the control unit passes this check, there are no false
signals entering the control unit.
PASS:
1.
Disconnect power from the control unit.
2.
Open the enclosure cover and re-attach the coaxial cable connector to the
control unit.
3.
Close the enclosure cover and proceed to the Coaxial Cable Zero Check.
FAIL:
1.
If a zero reading cannot be obtained, close the enclosure cover and contact
the factory for further assistance.
COAXIAL CABLE ZERO CHECK
1.
Disconnect power to the control unit.
2.
Open the sensor enclosure cover and disconnect the coaxial cable center
conductor from the sensor probe end. Do not disconnect the coaxial cable
shield. Do not remove the probe from the process. Leave the coaxial cable
center conductor ring terminal hanging in free space within the sensor
enclosure (do not isolate it with tape) and close the cover.
3.
Re-apply power to the control unit and allow the reading to stabilize for 1-2
minutes.
4.
Read the display. It should be below the control units specified minimum
detection level. If the coaxial cable passes this check then there are no false
signals entering the coaxial cable.
PASS:
1.
Disconnect power to the control unit.
2.
Open the sensor enclosure cover and re-attach the coaxial cable center
conductor to the sensor probe end.
3.
Close the sensor enclosure cover and proceed to the sensor zero check.
FAIL:
Document No. 210-1003-M
1.
Check cable installation and routing instructions in the Installation section
of this manual for proper cable installation. Make any changes necessary.
2.
Contact the factory for further assistance.
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©2007
Particulate Monitoring Systems
Installation & Operating Manual
Once the control unit and coaxial cable zero have been checked, proceed to the Sensor Zero Check.
To perform the sensor zero check the process flow must be stopped or a sensor test pipe (available
from Factory) or length of metal pipe will be needed (4”-6” diameter pipe or larger). The pipe should
be at least 3 in (8 cm) longer than the probe itself and must be grounded. The length of pipe will serve
as an electrical shield for the probe while it is out of the process.
SENSOR ZERO CHECK
1.
Do not remove the sensor from a running process if it will in any way
compromise personnel, plant safety or hazardous area safety procedures.
2.
Disconnect power to the control unit.
3.
Remove the sensor from the process and insert it into the grounded metal
test pipe. For hazardous area sensors do not disconnect the external sensor
earth ground strap.
4.
Re-apply power to the control unit and allow the reading to stabilize for 1-2
minutes.
5.
Read the display. It should be below the control units specified minimum
detection level. If the sensor passes this check there are no false signals
from the sensor.
PASS:
1.
Disconnect power to the control unit.
2.
Remove the sensor from the grounded test pipe and re-insert into the
process. For hazardous area sensors do not disconnect the external sensor
ground strap.
FAIL:
1.
Contact the factory for further assistance.
When performing a zero check, keep in mind that it may be acceptable to consider a small false signal
negligible. For example if the baseline readings are 100pA and a system zero offset of 1pA was
found, this is only a 1% affect on the normal readings. If using the device for basic flow/no flow
detection or basic emissions detection, this would not be significant.
Document No. 210-1003-M
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©2007
Particulate Monitoring Systems
Installation & Operating Manual
8. Automatic Self Checks
An optional self check subsystem is available to automatically verify calibration and proper operation
of the electronics, sensor and cable. Self checks can be performed while the system is online and
monitoring particulate. No external test equipment or operator intervention is required to activate or
complete the self check routines. Any errors detected by the self checks are reported through the
display, 4-20mA, relay and Modbus® outputs. The following automatic self checks are performed:
•
Control Unit Hardware Check
•
Control Unit Calibration (Zero and Span)
•
Sensor Cable Check
•
Particulate Sensor/Probe Check
The control unit zero and span self checks that are performed meet all requirements of the EPA
MACT Quality Assurance specifications. Self checks are automatically run every hour. A manual Self
Check may be activated anytime through the control unit keypad.
8.1
Control Unit Hardware Check
The Control Unit Hardware Check is an automatic check of all major electrical components in the
control unit. This check is automatically performed each time power is applied to the control unit.
Check
Watchdog Timer
SRAM
Description
Monitors all program tasks running in the microprocessor and
automatically resets the processor in the event of lock-up.
Checks the integrity of the SRAM memory.
Non-Volatile
Memory
Checks the integrity of the Non-Volatile memory. The results of this
check produce a checksum value which is analyzed each time a nonvolatile memory write occurs.
Option Board
Checks for proper installation of Power Supply, RS-485 and Self
Check option boards.
Analog Converter
Calibration
Checks calibration of the 22 bit high resolution analog converter.
Document No. 210-1003-M
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Particulate Monitoring Systems
8.2
Installation & Operating Manual
Control Unit Zero Check
The Zero Check will verify instrument zero calibration. The internal self check subsystem will
automatically perform the following procedure:
1.
Electronic disconnect of the particulate sensor cable
2.
Allow the reading to stabilize
3.
Measure the reading and compare to the allowable zero tolerance
4.
Electronic re-connect of the particulate sensor cable and resume normal operation.
There are four independent methods to activate the zero check:
Method
Description
Power-Up
A zero check is automatically performed each time power is applied to
the control unit
Keypad
Automatic
The operator may activate a zero check manually through the control
unit keypad. Reference Menu #2 setup tree for complete details.
The control unit may be configured to automatically perform a zero
check on a period basis. A re-settable delay timer controls the time
period between self checks. The delay timer is set to 1 hour by default.
The delay timer is reset each time self checks are performed regardless
of the activation method.
Automatic self checks may be activated at preset hourly, daily and
monthly dates/times when connected to a computer running the
FilterWare Visualization application.
Remote
Document No. 210-1003-M
The operator may activate a zero check manually when connected to a
remote computer running the FilterWare Visualization application.
Alternately, self checks may be independently activated from any
remote PC or PLC with Modbus® communication capability.
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Particulate Monitoring Systems
8.3
Installation & Operating Manual
Control Unit Span Check
The Span Check will verify the instrument span calibration. The internal self check subsystem will
automatically perform the following procedure:
1.
Electronic disconnect of the particulate sensor cable
2.
Electronic input of a calibrated pA reference signal
3.
Allow the reading to stabilize
4.
Measure the reading and compare to the allowable span tolerance
5.
Electronic disconnect of the reference signal
6.
Electronic re-connect of the particulate sensor cable and resume normal operation.
There are four independent methods to activate the span check:
Method
Description
Power-Up
A span check is automatically performed each time power is applied
to the control unit
Keypad
The operator may activate a span check manually through the control
unit keypad. Reference Menu #2 setup tree for complete details.
Automatic
The control unit may be configured to automatically perform a span
check on a period basis. A re-settable delay timer controls the time
period between self checks. The delay timer is set to 1 hour by default.
The delay timer is reset each time self checks are performed regardless
of the activation method.
Automatic self checks may be activated at preset hourly, daily and
monthly dates/times when connected to a computer running the
FilterWare Visualization application.
Remote
8.4
The operator may activate a span check manually when connected to a
remote computer running the FilterWare Visualization application.
Alternately, self checks may be independently activated from any
remote PC or PLC with Modbus® communication capability.
Sensor Cable Check
Integrity of the sensor cable is checked using advanced digital signal processing algorithms. The cable
check operates continuously and does not interfere with normal monitoring of the process particulate
signal. The sensor cable check is disabled while zero or span checks are being performed.
For proper operation of the sensor cable check a process running signal must be provided to the
control unit. Reference section 8.6 for full details.
8.5
Particulate Sensor Check
Operation of the particulate sensor/probe is checked using advanced digital signal processing
algorithms. The particulate sensor check operates continuously and does not interfere with normal
monitoring of the process particulate signal. The particulate sensor check is disabled while zero or
span checks are being performed.
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8.6
Installation & Operating Manual
Process Running Signal
A process running signal indicates to the control unit whether the main process fan is ON or OFF.
Connection of a process running signal adds the following capabilities to the automatic self check
subsystem:
1.
Sensor cable check – reference section 8.4 for further details.
2.
Automatic system zero – verifies zero of the total system electronics, cable and sensor while fully
installed in the process.
For proper operation the following conditions must be met:
8.7
1.
A process running signal must be connected to the control unit process run relay input channel.
This signal must be provided from an isolated, non-powered relay contact that closes when the
main process fan is on, and opens when the main process fan is off. A motor starter auxiliary
contact and/or separate control relay are typically used to provide this signal to the control unit.
Refer to the installation drawings for details on making connections to the relay input channel.
2.
The process run relay input channel must be enabled for use. Reference menu #2 setup tree for
complete details.
Monitoring Self Check Status
There are four independent methods to monitor the status of the self check subsystem.
LCD Display
The control unit’s LCD display will indicate the current status of the self check subsystem as listed
below:
PV Units Display
‘pA’ or ‘mg’
Indication
No self checks currently running. The most recent self checks were
successful, no failures
‘SC1’
Zero check in process
‘SC2’
Span check in process
‘ER1’
Zero error
‘ER2’
Span error
‘ER3’
Sensor error
‘ER4’
Cable error
‘ER5’
SRAM error
‘ER6’
Non-Volatile memory error
‘ER7’
Option board error
‘ER8’
Analog converter error
‘ER9’
System zero error
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Alarm Relay
An alarm output relay can be activated if any self checks are unsuccessful. The alarm relay will
remain activated until a subsequent self check is performed successfully, or power to the control unit
is disconnected. Alarm relay #1 will be activated in the event of a self check failure by default. Alarm
output relays may be configured to operate in normal or fail-safe modes.
4-20mA Output
The 4-20mA output will be driven to non-standard levels to indicate self check status as listed below:
mA Output
Indication
3.8mA
Zero or span check in process, sensor is disconnected
3.6mA
A self check error has occurred
Serial or Ethernet Communication Network
All information regarding status, control and setup of the self check subsystem is accessible as
register data through the control unit’s communication network. See the Modbus® register map at the
end of this document for a complete detailed listing of registers data available.
8.8
Particulate Alarming During Self Checks
All particulate alarms are put in a suspend mode while a self check is being performed. When a self
check is completed, all particulate alarms will resume normal operation.
8.9
Self check Recording
EPA MACT regulations require that plants maintain a record of all self checks performed. To reduce
the number of plant personnel required to generate these records, the control unit provides two
methods suitable for automated record generation.
4-20mA Output
The 4-20mA output will be driven to specific, non-standard levels to indicate that self checks are
being performed and if any self check has failed. A PLC may be easily configured to monitor for
these specific, non-standard, mA levels and transmit status information to a central plant information
network for record storage.
Serial or Ethernet Communication Network
The overall status of each self check, as well as the results of the most recent self checks performed,
are accessible through the Modbus® network port. This information may be monitored and logged
with a remote PC running SCADA application software. Optional FilterWare Visualization and
Reporting software is available to monitor all of the control units self check information and
automatically generate MACT compliant self check reports.
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9. Troubleshooting
The following is primarily used when troubleshooting a system without the optional automatic self
checks. When troubleshooting, consider each component of the system: The control unit, the sensor
coax cable and the sensor assembly.
False High Signals (False Alarms)
1. When an apparent false high signal is present, first check the process to be sure the particulate
level has not increased. Keep in mind that the system can detect very low levels. In filtration
applications the system can detect invisible particulate levels and very small emissions.
2. Check the sensor cover and conduit seal to be sure they were not left open allowing rain to enter
the housing. Check the coaxial cable connectors using a digital voltmeter and check for shorts. If
nothing can be found, conduct a manual system zero check.
No Reading or Alarm (When Believed Necessary)
1. Increase the particulate level or introduce particulate into the air stream and monitor for a response.
If the system responds properly re-evaluate the selected alarm points and the process conditions.
2. If there is no response, check for electrical continuity from the sensor to the control unit end of the
coax cable.
3. Contact the factory for a Field Test Unit that can generate a signal to check response and
calibration.
10. Routine Maintenance
EQUIPMENT MAINTENANCE
•
Only appropriately licensed professionals should perform maintenance on
this product.
•
For operator safety and to prevent ignition of flammable or combustible
atmospheres always disconnect power before servicing.
Particulate Sensor: There is no electronic calibration or zero adjustment for the sensor. The sensor
does not normally need any cleaning and for optimal performance, routine cleaning of the sensor is
not recommended.
Control Unit: The viewing window, keypad and enclosure may be cleaned with soap and water as
needed. Use a soft cloth to prevent scratching the window. Do not use an abrasive pad or any
chemicals that will attack plastic or Lexan.
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Installation & Operating Manual
11. Spare Parts
Item
Line Fuse, 115/230VAC
Details
0.032A 250V Slo-Blo type ‘T’
Mfr Part No.
LittleFuse
218.032
0.050A 250V Slo-Blo type ‘T’ when
Self Check Option is installed
LittleFuse
218.050
Line Fuse, 24VDC
0.250A 250V Slo-Blo type ‘T’
Control Unit
Control Unit Family
Refer to Product Label
Particulate Sensor
Variable Lengths & Connections
Refer to Product Label
Particulate Sensor Cable
Coax, SMA x Ring Lugs
Document No. 210-1003-M
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218.250
CCA-Feet
©2007
Particulate Monitoring Systems
Installation & Operating Manual
12. Appendix
Modbus®/RTU RS-485 Networking Protocol
Ethernet/IP® Networking
Installation & Hazardous Area Control Drawings
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12.1 Modbus®/RTU RS-485 Networking Protocol
The RS-485 networking feature allows up to 32 control units to be connected to a multi-drop
communications network. When connected to the network, any device on the network may be
monitored and controlled by a remote device such as a PLC or Computer using Modbus®/RTU
protocol.
Network Hardware Description
RS-485 is a standard industrial network used for serial communications between multiple devices
from a single connection. Electrical communication signals are transmitted differentially providing
immunity to electrical noise and power supply variances. Signals are transmitted between devices
over a single twisted pair wire with shield. Communications are half-duplex (cannot transmit and
receive at the same time). Serial baud rate is fixed at 19,200 bps. The serial frame is fixed at 8 data
bits, 1 stop bit and no parity. Communications are supported over a maximum network length of 4000
feet. When connecting more than two devices on the network, all devices should be wired ‘in-line’
and not in a ‘star’ configuration.
A terminating resistor must be present at each end of the RS-485 network to eliminate transmission
reflections on the serial line. Some control units contain a two-position jumper to allow the device to
be either terminated (T) or un-terminated (U). The terminating resistor connected in the (T) position is
120Ohms. All other devices on the network that are not at a network end must be set to un-terminated
(U). For control units that do not contain a terminating jumper, a 120ohm ½ watt resistor may be
placed across the RS-485 +/- output terminals.
PLC Connection
Connection to plant PLC’s is dependant upon the communications ports available on the specific PLC
being used. Ensure that the communications port connected to is not limited to a PLC manufacturer’s
proprietary network protocol such as Allen-Bradley Data-Highway or Remote I/O. Modicon’s
Modbus® “Plus” protocol is also not supported. This is a Modbus® RTU protocol.
Some configuration may be required in the PLC to set the communications port to Modbus®/RTU.
RS-485 Communications Ports
A network connection may be directly wired to any communication ports that support half-duplex RS485 and Modbus®/RTU protocols. Refer to the PLC manufacturer’s literature for specific details on
connections to the PLC communications port.
Network connections to RS-232/RS-232C or RS-422 ports are supported with the addition of a
converter module. As with the RS-485 port, the Modbus®/RTU protocol must be supported for proper
operation. Converter modules are available from the factory. The converter module modifies the
voltage levels and wiring connections to allow different RS connections to work together. Converter
modules generally require their own power source, which must be provided in the PLC cabinet.
When using an RS-485 to RS-232 converter the converter must be setup so it will transmit when the
TD line is asserted.
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Personal Computer Connection
Connection to a personal computer is made to the RS-232 COM port with the addition of a converter
module. Converter modules are available from the factory. The converter module modifies the voltage
levels and wiring connections to allow different RS connections to work together. Converter modules
generally require their own power source, which may be supplied with a wall-mount transformer
power supply.
Network Protocol Description – Modbus®/RTU
The communication protocol used to transmit data between network nodes is Modbus®/RTU
developed by Modicon. Devices communicate using a master-slave technique, in which only one
device (the master) can initiate transactions (queries). The other devices (slaves) respond by supplying
the requested data to the master, or by taking the action requested in the query.
When using our PC software packages the Modbus® protocol is coded into the software so that
configuration and operation of the network devices and software is simple. The user has no need to
know the specifics of the Modbus® protocol or the types of messages sent and received. All of the
low-level communications functions are taken care of and are transparent to the system user. The PC
running our software is configured as the network master and all other devices on the network are
configured as slaves.
Modbus® Message Description
The Modbus® protocol establishes the format for the master’s query by placing into it the device
address, a function code defining the requested action, any data to be sent, and an error-checking field.
The slave’s response message is also constructed using Modbus® protocol. It contains fields
confirming the action taken, any data to be returned, and an error-checking field. If an error occurred
in receipt of the message, or if the slave is unable to perform the requested action, the slave will
construct an error message and send it as its response.
Three data types are supported:
Discrete (1-bit)
Integers (16-bit)
IEEE Floating point (32-bit)
Modbus® Protocol Function Codes
Code
01
02
03
04
05
06
07
15
16
17
Document No. 210-1003-M
Function
Read Coil Status
Read Input Status
Read Holding Register
Read Input Register
Force Single Coil
Preset Single Register
Read Exception Status
Force Multiple Coils
Preset Multiple Registers
Report Slave ID
Description
Reads digital outputs or 1 bit data registers
Reads digital inputs or 1 bit data registers
Reads analog outputs or 16 bit data registers
Reads analog inputs or 16 bit data registers
Writes digital outputs or 1 bit data registers
Writes analog output or 16 bit data register
Reads status information
Writes digital outputs or 1 bit data registers
Writes analog outputs or 16 bit data registers
Reads device type information
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Modbus®/RTU Registers
Register
Description
Address
0x Reference: Discrete output coils
00001 Alarm relay 1 (1=ON, 0=OFF)
00002 Alarm relay 2 (1=ON, 0=OFF)
03073 Alarm status - alarm 1 (1=ON, 0=OFF)
03074 Alarm status - alarm 2 (1=ON, 0=OFF)
03247 Zero Check Running Status (1=Running, 0=Not Running)
03248 Span Check Running Status (1=Running, 0=Not Running)
03249 Full System Zero Check Running Status (1=Running, 0=Not Running)
03251 Zero Check Remote Activation (Set to 1 to Activate)
03252 Span Check Remote Activation (Set to 1 to Activate)
03254 Probe & Cable Check Status (1=Error, 0=OK)
03255 Zero Check Status (1=Error, 0=OK)
03256 Span Check Status (1=Error, 0=OK)
03257 Full System Zero Check Status (1=Error, 0=OK)
Description
4x Reference: Holding registers
40609 Process Variable 1 - particulate (pA)
40611 Process Variable 2 - averaged particulate (pA)
42309 Correlation Scaling Raw Minimum (pA)
40705 Correlation Scaling Raw Maximum (pA)
40641 Correlation Scaling Scaled Minimum (mg/m3 or gr/ft3)
40647 Correlation Scaling Scaled Maximum (mg/m3 or gr/ft3)
40721 Process Variable Units of Measure (0=pA, 1=mg/m3, 2=gr/ft3)
40737 Alarm 1 Level - (pA)
40739 Alarm 2 Level - (pA)
40769 Alarm 1 delay - (sec)
40770 Alarm 2 delay - (sec)
43363 Zero Check Delay Between Checks (Hours)
43365 Span Check Delay Between Checks (Hours)
43367 Full System Zero Check Delay Between Checks (Hours)
43381 Probe & Cable Check Relay to Activate (0=None, 1=Relay 1, 2=Relay 2)
43382 Zero Check Relay to Activate (0=None, 1=Relay 1, 2=Relay 2)
43383 Span Check Relay to Activate (0=None, 1=Relay 1, 2=Relay 2)
43384 Full System Zero Check Relay to Activate (0=None, 1=Relay 1, 2=Relay 2)
43399 Zero Check Allowable Tolerance (pA)
43404 Span Check Allowable Tolerance (pA)
43409 Full System Zero Check Allowable Tolerance (pA)
43401 Zero Check Settling Time (milliseconds)
43406 Span Check Settling Time (milliseconds)
42402 Result Measured from Last Zero Check (pA)
42407 Result Measured from Last Span Check (pA)
42412 Result Measured from Last Full System Zero Check (pA)
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Data
Type
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Bit
Float
Float
Integer
Integer
Integer
Integer
Integer
Float
Float
Integer
Integer
Float
Float
Float
Integer
Integer
Integer
Integer
Float
Float
Float
Integer
Integer
Float
Float
Float
©2007
Particulate Monitoring Systems
Installation & Operating Manual
12.2 Ethernet/IP® Networking
The Ethernet/IP® networking feature allows communication between control units and other
devices on an Ethernet/IP® network. Ethernet/IP® is a common networking protocol supported by
Allen-Bradley equipment and other third party vendors.
Network Hardware Description
Ethernet is one of the most common networking topologies in use today. Devices on the Ethernet
network are connected to a central Ethernet switch which links devices together and filters network
traffic. Devices must be connected directly to a switch using a standard Category 5e Ethernet
cable, or directly to another Ethernet device using a crossover Category 5e Ethernet cable. The
maximum length supported for a single Ethernet connection is 100 meters, additional lengths
require installation of switches/repeaters or alternate networking hardware such as fiber optics.
Ethernet networks typically run at a speed of 100Mbps. Both 10Mbps and 100Mbps data rates are
supported by the control unit with an auto-sensing Ethernet PHY interface.
The control unit is available with a Modbus®/RTU RS485 communication port located directly
within the control unit enclosure. The particulate monitor’s Ethernet/IP® interface is typically
supplied as an external converter housed in a separate enclosure due to the limited space within the
standard control unit enclosure. The Ethernet/IP® converter translates between Ethernet/IP®
network messages and Modbus®/RTU control unit messages. With this functionality the control
unit appears as an ordinary Ethernet/IP® device on the Ethernet network.
Network Protocol Description
Ethernet/IP® is an open networking protocol governed by the Open DeviceNet Vendor Association
(ODVA) and was originally developed by Allen-Bradley. It is built upon a producer/consumer
connection structure where data is grouped into assemblies for transmission over the network.
Connections between devices requiring communications on an Ethernet/IP® network are created as
either an I/O or Explicit messaging type. Explicit connections are supported only for factory
configuration data, no user data is available over an explicit connection. A maximum of 1
Ethernet/IP® I/O connection and 2 Ethernet/IP® TCP connections are supported.
The TCP stack currently being used does not properly support TCP Keepalive functionality.
Therefore, when an Ethernet/IP® UDP I/O connection is established, if there is no Ethernet/IP
activity on the parent TCP connection, the UDP and TCP connections will time-out after 30
seconds. This can be easily avoided by adding a periodic Get_Attribute_Single request (every 1520 seconds is fine) from the I/O client. This request will keep the TCP connection alive and
prevent time-out from occurring.
For complete details on the Ethernet/IP protocol visit the ODVA website at www.odva.org.
Explicit Message Connections
Changes to the Ethernet/IP® module’s internal configuration are accomplished with explicit
messages. Contact the factory for further information on internal configuration changes above and
beyond IP address and Subnet mask.
Explicit messages may be issued by various software packages, most typically RSNetworx® for
Ethernet/IP® from Rockwell Software or EIPScan® from Pyramid Solutions. From within
RSNetworx® for Ethernet/IP® explicit messages may be issued with the Class Instance Editor as
shown below:
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Network Addressing and BOOTP Behavior
Communication over an Ethernet network typically requires a device to be setup with two
addressing parameters, a MAC address and an IP address. The MAC address of the Ethernet/IP®
module is fixed and is listed on the enclosure.
The IP address is set to a factory default value of 192.168.0.254 with subnet mask 255.255.255.0
when shipped. To change the IP address a BOOTP server must be present on the Ethernet network.
The following procedure is used to change the IP address:
1.
The Ethernet/IP® module must be unlocked to allow changes to its internal configuration. By
default the module is locked at power-up. To toggle the lock state the following explicit
message must be sent to the module:
Service
0x45
Class
0x67
Instance
0x89
Attribute
0xAB
Data
0xCD
2.
BOOTP operation within the module must be ENABLED. By default BOOTP operation is
disabled. After the IP address has been set BOOTP operation must be set back to disabled.
To ENABLE BOOTP operation the following explicit message must be sent to the module:
Service
Class
Instance
Attribute
Data
0x10
0x64
0x01
0x6E
0x01
3.
Launch a BOOTP server on the network and configure it with the MAC address of the module
and the desired new IP address and Subnet mask.
Cycle power to the module. Once power is re-applied the module will broadcast a BOOTP
request for an IP address. The BOOTP server should respond by assigning the desired IP
address to the module.
Unlock the module again to allow changes to the configuration. To toggle the lock state the
following explicit message must be sent to the module:
4.
5.
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Particulate Monitoring Systems
6.
7.
8.
Installation & Operating Manual
Service
Class
Instance
Attribute
Data
0x45
0x67
0x89
0xAB
0xCD
BOOTP operation within the module must be DISABLED. To DISABLE BOOTP operation
the following explicit message must be sent to the module:
Service
Class
Instance
Attribute
Data
0x10
0x64
0x01
0x6E
0x00
Cycle power to the module. Once power is re-applied the module will come online with the
new IP address and Subnet mask. BOOTP operation should be disabled at this point so no
BOOTP requests will be issued by the module.
A network ping should be used to verify that the IP address and Subnet mask have been set
correctly.
The control unit must always be configured with Modbus®/RTU RS-485 network address set to 1.
Input (T->O) Assembly Object (Class 0x04, Instance 0x65)
The following is a mapping of I/O values for the standard Ethernet/IP® assembly object instance
0x65. These are values that are sent from the Ethernet/IP® server (control unit) to the Ethernet/IP
client (typically a PLC). The input assembly size is 13 (16 bit words).
Data Types
Bool – 1 bit Boolean discrete data
Usint – 16 bit unsigned integer analog data
Sint – 16 bit signed analog data
Float – 32 bit signed floating point analog data
Floating point values are represented in IEEE format (32-bit) where the 1st register is the LOW
word and the 2nd register is the HIGH word.
Input (T->O) Assembly Object (Class 0x04, Instance 0x65) Size 13 (16 bit words)
16-Bit
Word
Address
0
1
1:0
1:1
2
2:0
2:1
2:2
Modbus®
Range
Range
Address
03073
03074
03247
03248
03249
Min
0
0
0
0
0
0
0
0
2:3
2:4
03251
2:5
2:6
2:7
2:8
2:9
2:10
Data
Type
Description
Max
65535
65535
1
1
65535
1
1
1
Usint
Usint
Bool
Bool
Usint
Bool
Bool
Bool
0
0
1
1
Bool
Bool
03252
0
1
Bool
03254
03255
03256
03257
0
0
0
0
0
1
1
1
1
1
Bool
Bool
Bool
Bool
Bool
Network status (0=ok, >0=error)
Alarm status 1-16 (1 = alarm, 0 = ok)
Alarm status – Max alarm #1 (1=ON, 0=OFF)
Alarm status – Pre-Visible alarm #2 (1=ON, 0=OFF)
Self check status information
Zero check status (1=RUNNING, 0=NOT RUNNING)
Span check status (1=RUNNING, 0=NOT RUNNING)
Full system zero check status (1=RUNNING, 0=NOT
RUNNING)
Not Used
Zero check remote activate (1=ACTIVATED, 0=NOT
ACTIVATED)
Span check remote activate (1=ACTIVATED, 0=NOT
ACTIVATED)
Not Used
Probe and cable check status (1=ERROR, 0=OK)
Zero check status (1=ERROR, 0=OK)
Span check status (1=ERROR, 0=OK)
Full system zero check status (1=ERROR, 0=OK)
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Units
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2:11
Thru
2:15
3
4
5
6
7
8
9
10
11
12
-
0
1
40609
40610
40611
40612
40737
40738
40739
40740
40769
40770
0
5000
0
Installation & Operating Manual
Bool
Not Used
pA
Float
5000
pA
Float
0
5000
pA
Float
0
5000
pA
Float
0
0
600
600
Particulate process variable LO word
Particulate process variable HI word
Averaged particulate process variable LO word
Averaged particulate process variable HI word
Alarm level – Max alarm #1 LO word
Alarm level – Max alarm #1 HI word
Alarm level – Pre-visible alarm #2 LO word
Alarm level – Pre-visible alarm #2 HI word
Alarm delay – Max alarm #1
Alarm delay – Pre-visible alarm #2
Usint
Usint
Output (O->T) Assembly Object (Class 0x04, Instance 0x66)
The following is a mapping of I/O values for the standard Ethernet/IP® assembly object instance
0x66. These are values that are sent from the Ethernet/IP® client (typically a PLC) to the
Ethernet/IP® server (control unit). The first word in the map contains the run/idle bit (bit 0). The
run/idle bit controls write access to the control unit. When the run/idle bit is set to 0 the control
unit is set to idle mode. In idle mode, the Ethernet/IP® server will allow read only access to the
control unit. When the run/idle bit is set to 1 the control unit is set to run mode. In run mode, the
Ethernet/IP® server will allow both read and write access to the control unit. The run/idle control
is defined for communications purposes only and has no affect on any other normal
control/sensing/alarming operation of the control unit. The output assembly size is 7 (16 bit
words).
Data Types
Bool – 1 bit Boolean discrete data
Usint – 16 bit unsigned integer analog data
Sint – 16 bit signed analog data
Float – 32 bit signed floating point analog data
Floating point values are represented in IEEE format (32-bit) where the 1st register is the LOW
word and the 2nd register is the HIGH word.
Output (O->T) Assembly Object (Class 0x04, Instance 0x66) Size 7 (16 bit words)
16-Bit
Word
Address
0
1
2
3
4
5
6
Modbus
®
Address
40737
40738
40739
40740
40769
40770
Range
Range
Units
Min
0
0
Max
1
5000
0
0
0
Document No. 210-1003-M
Data
Type
Description
pA
Usint
Float
5000
pA
Float
600
600
Sec
Sec
Usint
Usint
Run/Idle mode setting (0=idle/read only, 1=run/read write)
Alarm level – Max alarm #1 LO word
Alarm level – Max alarm #1 HI word
Alarm level – Pre-visible alarm #2 LO word
Alarm level – Pre-visible alarm #2 HI word
Alarm Delay HI Particulate
Alarm Delay HI Delta P
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©2007
Particulate Monitoring Systems
Installation & Operating Manual
Configuration Assembly Object (Class 0x04, Instance 0x80)
The configuration assembly object is not implemented. However, some Ethernet/IP® clients
require one. If this is the case, use Instance ID 0x80 with a data length of 0.
Document No. 210-1003-M
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©2007
Particulate Monitoring Systems
Installation & Operating Manual
Notes:
Document No. 210-1003-M
Page 42
©2007
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