Dwyer DPM User Manual

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Particu late Moni tori n g Sy s tems

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

Particu late Moni tori n g Sy s tems 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: tech@dwyer-inst.com

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.

Particu late Moni tori n g Sy s tems 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 Dwye r 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 an y claim b y any oth er par ty.

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

Identifies information that is critical for successful application and

IMPORTANT

Identifies information, sections or statements in this manual that apply to

understanding of the product.

approved hazardous area systems, regulations or installation.

Particu late Moni tori n g Sy s tems 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:

Particulat e Se nsor:

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, -25ºC to 70°C, with intrinsically-safe output to Particulate Sensor.

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.

Particu late Moni tori n g Sy s tems Installation & Operating Manual

IV. Specifications

PARAMETER DETAIL SPECIFICATION NOTE

Input Voltage 115V~

230V~

24VDC

Input P ower 6 Watts Max.

Measurement Units picoamperes (pA) 1 x 10 ⎯ ¹² Amp

Detection Level/Range

Electronic Accuracy

Temperature Range

Relay Outputs

4-20mA Output (Optional)

RS-485 Network (Optional)

Enclosure Type

Mounting

Materials

Process Temperature Range Operating

Ambient Temperature Range Operating

Pressure Range Operating Full Vacuum to 10PSI (2.11kg/cm²) Higher Optional

Enclosure

Standard 5.0pA – 5000pA Optional 0.5pA – 5000pA

Operating

Storage

Type Form A (SPST)

Rating

Type Isolated

Rating 470Ω Max. Loop Impedance

Span Adjustable Via Keypad Default: 1000pA LOG Type Isolated, Multi-drop, ½ Duplex

Settings 19,200 BPS, 8 Data Bits, 1 Stop Bit, No Parity

NPT ½” NPT Thread

QC 1.5” Quick-Clamp (Mounting ferrule is 1” NPT)

FL ANSI Flange (2”, 150# is typical)

Other Others Available

Probe

Nipple/Mount Stainless Steel

Type Painted Cast Aluminum Other - Consult Factory

Rating NEMA 4X (IP 66) Other - Consult Factory

CONTROL UNIT

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’

± 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)

5A @ 240V~ Resistive **Customer must provide a

8A (maximum) fuse in series with relay load.

Painted Cast Aluminum NEMA 4X or optional CSA

Approved Enclosure

PARTICULATE SENSOR

Stainless Steel

With Protective Teflon Layer

-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 Maximu m (-40 °C to +70°C)

Maximum Must be Calculated for each application

Selector Switch to 115V

Selector Switch to 230V

No Select or Swit ch

Optional Model

Over Fu ll Temp Range

Modbus/RTU Protocol

Other optional

Higher Optional

T-Code Ratings for

AHZ1 option only

Document No. 209-1025-D

Particu late Moni tori n g Sy s tems Installation & Operating Manual

PARAMETER DETAIL SPECIFICATION NOTE

Type High Quality Coaxial

Temperature Range

Maximum Len gth 300 ft.

Approximate Particulate

Concentration

Velocity Range 150 ft/min. (45.7 m/min.) and Higher

Particle Size Range

Operating

DETECTION LEVEL/RESO LUTI ON AND APPLICATION RANGE

5.0pA

Standard

0.5pA

Upgrade

PARTICULATE SENSOR CABLE

-40°F to +392°F (-40°C to +200°C)

At least 5.0 – 5000 mg/m³ At least 0.002 to 2.0 gr/ft³

At least 0.5 to 5000 mg/m³ At least 0.0002 to 0.2 gr/ft³

0.3 Micron and higher If <10.0 Micron, 0.5pA Detection Required

Barely Visible to Visible

>5% Opacity

Moderate Dilute Flow

Invisible to Barely

Visible, < 5% Opacity

Light Dilute Flow

Document No. 209-1025-D

Particu late Moni tori n g Sy s tems Installation & Operating Manual

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 1 Hazardous Area Control Drawing

Document No. 209-1025-D

Particu late Moni tori n g Sy s tems Installation & Operating Manual

TABLE OF CONTENTS

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 Senso r Te mperatu re 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 Ch eck................................................................................................................. 28

8.5 Particulate Sen sor 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

Particu late Monitoring Sy s tems Installation & Operating Manual

1. Safety

1.1 Applicable Use

These particulate monitor systems ar e 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 safet y system. Th es e m on itors are designed for general process and environ mental moni toring.

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 elec tric al equipment for measurement, control and laboratory u s e, and are s u pp lied in a safe condition. Before beginning an installation the following safety precautions and all precautions noted listed throughout this manual and in the installation drawin gs 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 classificati on .

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

mechan ical and el ectrical ins tallation.

• 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

atmospher es 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, vol tage and specified type should be

used. D o n ot u s e r ep aired fuses or short-cir cu ited fuse hol d er s .

REGULATORY CODES

• Installation and operation must adhere to all national an d local codes.

Particu late Monitoring Sy s tems Installation & Operating Manual

1.3 Hazardous Area Syste ms

Systems approved for use in hazardous areas include nameplates indicating that they a re suitable for inst allation in hazard ou s areas. The nameplate list s 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 classifica tion.

Section s or st at emen ts in thi s man ua l tha t a pply to a pproved ha zar dous ar ea syst ems or in s tall at ion s are designated with the following symbol. Designation for use in hazardous areas does not make the system su itable for use as a functi onal safety device.

EXPLOSION HAZARD

• Hazardous area control drawing 225-1005 must be followed for proper

installation.

• Installation mu st be in accord ance with ANS I /ISA RP12.6 an d 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

suit able for use as a fun ctional safety device.

Particu late Monitoring Sy s tems Installation & Operating Manual

2. Introduction

A Parti culate Mon itorin g System con sist s of a contr ol unit, a par ticul ate sensor and a sen sor coaxia l 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 pr ovided 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 air flow stream such as a pipe, duct or stack (for small tubing an inline nonintr usive ring sen sor is employed). As particul ate flows near and over the sen sing element, minut e electr ical cur rents ar e induced in th e sensor an d transfer red to th e control unit by a coa xial cable. A microprocessor filter s and processes the signal into a normalized, absolute output that is lin ear to the mass concentrat ion of particu late.

_ MASS CORRELATION

IMPORTANT

It is important to note that the above relation between instrument units (pA) and actual mass (mg/m appropriate model and range and for providi ng a general indic ation of the typic al particulate levels monitored. For a true correlation between (pA) and actual mass (mg/m must be performed for each application and a recommended model and detection level must be ordered. It is also important to note that th e 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 techn iques. Consult factor y for detail s.

or gr/cf) is just an approximate guide for selecting the

or gr/cf), a gravimetric correlation such as an isokinetic sample

Control Unit

The con trol un it (i .e. el ectroni cs) is h oused in a ru gged cast alumin um encl osure. An LCD di splays particulate levels in bar-graph and digital forms. A lockable membrane keypad is provided for setup and adjustment. An optional self ch eck sub system is available to automatically verify calibration and operation of the con trol unit, sen sor and cable. Various r elay, analog inputs and outputs, as well as seri al communications are ava ilable in the control unit.

Particulate Sensor

The particulate sensor is very rugged and vir tually 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 b y 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 desi g ned for the system. Maximum length i s 30 0 ft ( 9 1m ). Do not use substitute cable.

Particu late Monitoring Sy s tems Installation & Operating Manual

3. Control Unit Installation

3.1 Location

The foll o wi ng factors should be cons idered when d etermining the contr ol un it locati on:

 Locate at a position that is convenien t for setup and operation  Mount at eye level  Mount to a flat surface in a vertical orientation  Do not mount to surfaces with excessive heat or vibration

INSTALLATION PERSONNEL

• Only appropriately licensed professionals sh ould install this product.

• For operator safety and to prevent ignition of flammable or combustible

atmospher es always disconnect power before servicing.

CONTROL UNIT LOCATION

• The con trol 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 par t of an appr oved h aza rdou s ar ea syst em wi th a ppr oved c ontr ol un it an d approved sensor assembly.

• Do not l ocate the con trol unit in or n ear sources of very high elect rical n oi s e

such as a Variable Frequency Drive (VFD) or Motor Control Center. Locate the con trol unit at least 10 feet fr om thes e sources an d, if possibl e, power the control unit from a separate power source. If power is supplied from the same br anch cir cuit or a cir cui t con tainin g el ectri cal n oise, in st all a quali ty line filter such as an Islatrol IC+102.

Mounting: Mounting holes are in tegrated into the enclosure base. Mounting hardware should be

capable of supporting five times the control unit weight. Refer installa tion drawings for dimensions.

supplied as

3.2 Wiring

An appr opriatel y li censed electrician mu s t p er form all electrical connection s.

CONTROL UNIT WIRING

• All wiring must be rated 250V minimum.

• The con trol un it mu st be moun ted wit hin si ght of an appropr iate elect ri cal

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.

Particu late Monitoring Sy s tems 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 c onduit openings in the side or top of th e 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 intrin sic safet y ground. It is not suffi cient to use a single ground connection and jumper the protective and intrinsic safety grounds inside the control unit enclosure.

CONTROL UNIT GROUNDING

• Protective earth ground must be connected to t erminal #1.

• The enclosure co ver must be bonded to the enclosure base with the s u pplied

gr ound bonding wire – do n ot remove .

• When used a s par t of an approved haz ardous area system: Intr insic safet y

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 a s par t of an approved haz ardous area system: Intr insic safet y

ground must utilize a grounding electrode independent of the protective eart h ground.

Particu late Monitoring Sy s tems Installation & Operating Manual

4. Parti culate Sensor I nst allation

4.1 Location

The foll o wi ng factors should be cons idered when d etermining the sensor location:

 Area Classifica tion  Flow conditions  Electrical (Faraday) shi elding  Atmospheric shielding (in the case of ducts and stacks open to atmosphere)  Access for install at i on and service

SENSOR LOCATION

• Before installing the sensor, confirm ar ea classification r equirements. Do

not install any device that is not tagged suitable for the required area classificati on .

• Before installing the particulate sensor, confirm ambient temperature,

process t emperat ure and process pressur e requirem ents. Do not install an y 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 essent ial for th e pip e/duct to pr ovide a n el ectri cal (Far aday) sh iel d for t he sen sor. It is ther efore required that the pipe, duct or stack is metal and earth grounded (small inline tubing sensors pr ovide 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 th e particulate is evenly distributed. The ideal position is where the pipe/duct is straight and free of items such as valves, damp ers or ot her fl ow obst ructions for a l e ngth of 4 diameters or longer . Horiz ontal 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 measur em ent the n eed for a s tra igh t sect i on and lamin ar flow in creases. Th e par ti cul ate s en sor sh oul d be position ed with appr oximately two thirds of the straight section upstr eam 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 th e s ensor will interact with a r easonable rep resentat ion of the flow.

For emissions detection applications such as baghouses or cartridge collectors, good locations are generally found upstream of the blower. Th e particulate sensor can be located downstrea m of the blower but not too close to th e stack outlet. There must be sufficient duct downstream of the sensor to provid e adeq uat e electr ical and atmosp her ic shi eldin g. Th e sensor shoul d be locat ed up strea m of an y 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.

Particu late Monitoring Sy s tems Installation & Operating Manual

Extreme vibration should be avoided.

_ ATMOSPHERIC AND ELECTRICAL SHIELDING OF SENSOR

IMPORTANT

• 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

atmosph ere so wind driven atmospheric particulate or rain does not flow over the sensor and so ex ternal electrical n oi se cannot affect operati on .

• Do not p lace the sen sor where th e pipe/duct i s corroded or cr acked whi ch

may allow water droplets to create signals as they flow by.

4.2 Mounting

The foll o wing types of process moun ts are availa bl e for the stan dard probe style sensors: NPT, Quick-Clamp an d AN S I fl ange. 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 ca n be found in the appendix.

HAZARDOUS AREA SENSOR GROUNDING

• For hazardous area applications an external sensor earth ground cable is

require d to main tain sensor ground ing duri ng in stallat ion an d m ainte nance.

• The ground cable must remain attached when the sensor is temporarily

removed fr om the process – do not disconnect the ground cable.

• Leave sufficient ground cable service loop for easy removal of the sensor

from the process.

Particu late Monitoring Sy s tems Installation & Operating Manual

4.3 Sensor Temperature Considerations

The sensor may be ordered with on e 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 ran ge of 233ºC - 426ºC, a high temp probe must be used. The max imum allowab le ambie nt temp erature at sensor housing is 70ºC.

Table: T Code Rating for Sensor

Process Temperature Does Not Exceed

Maximum Ambi en t

75ºC (167ºF) 125ºC (257ºF) 225º C (437ºF) 325ºC (617ºF) 426ºC (800ºF)

70ºC (160ºF) T6 T4 T2C T1* T1*

Particu late Monitoring Sy s tems Installation & Operating Manual

5. Particulate Sensor Coaxial Cable Installation

Connection: Prior to making coaxial cable connections review the following routing in structions.

IMPORTANT

_ PARTICULATE SENSOR COAXIAL CABLE ROUTING

• The sensor cable must be installed in con duit that is separate from all other

wiring.

• The cabl e sh oul d be r ou ted from th e part i cula te s en sor t o the c ontrol unit in

a pa th t hat avoid s hi gh vi brat ion, hea t over 394 °F (200°C) and an y stron g magn etic or electrical field s.

• The cabl e should be locat ed at least 18 in (46 cm) away from an y p ower

lines (conduit), motors, frequency drives and other sources of electrical inter ference throughout its entire path.

• The cabl e shou ld be i nsta lled in metal lic con duit . At th e process en d, use a

section of shielded flex conduit that is 1 to 2 times the probe length to serve as a ser vice loop.

The coa xi a l ca ble i s c on n ected t o th e con t r ol un it by a coa x con n ector a nd is connected t o th e sen s or

by two ring terminal s . The connect ors are norma ll y sup p lied pre- assembled t o th e cable.

Once t he cable h as been r outed, in sert th e coax conn ector int o the contr ol unit enclosur e leavin g 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 th e control unit enclosure. If there is a significant amount of extra cable ( many feet), the cable sh ould be sh orten ed at th e sensor end and the sen sor end connector s should be re-assem bled using factory-supplied connectors and instructions.

IMPORTANT

_ COAXIAL CABLE INSIDE THE CONTROL UNIT

• A ferrite suppressor is located on the sen sor coaxial cable near the coax

connector and must remain inside the control unit enclosure.

• The bla ck ca ble i n sula ti on must ext en d a min imum of 6 i n (15 cm ) in t o th e

coax cabl e conduit .

• Do not l eave any excess ca bl e in the control unit or sensor housin g .

Insid e the particulate sensor encl osure, att ach the coax cable as in di cated in th e s ensor dra win g. When connecting the braided shield, ensure it does not touch the surge voltage protection assembly. Do not leave exc es s cable in side the sensor housing.

Particu late Monitoring Sy s tems Installation & Operating Manual

Sensor Test Port (Non-Hazardous Areas Only)

Location: A test por t should be installed in a negative pressure location. It must be located upstream

of the sens or s o pa rt i cu la t e ca n fl o w very nea r an d around t he s en s or . It sh ou l d be l oca t ed a t le a st 3 ft (1 m) upstream of th e sensor and it should be located on the same side of the duct as the sen sor 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 h ole, or welded in position. (Note: A foot or so of tubi n g can be con n ect ed t o th e nip pl e to ma ke it eas y to dr aw par ti cl es out of a conta iner. Only a pinch of particu late at a time is n eeded for a response check.)

_ TEST PORT INSTALLATION

IMPORTANT

• Installation of a sensor test port enables checking the response to an actual

increase in particulate.

Particu late Monitoring Sy s tems 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 dyn amic readings, which are typical with particulate flow.

Control Unit

The con trol unit has two alarm relays which are individually activated when the reading continuously exceeds the alarm setpoint for the amoun t of time delay specified. Each is an SPST (FORM A) r elay 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 th e associated alarm is active, or when power to the control unit is removed.

When th e r ea din g ex ceeds t h e a lar m s etp oint , the a l arm del ay timer is started. As long as th e 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 r emains above the alarm setpoint and th e alarm delay timer expires, an alarm is activated and the as sociated alarm relay cont act will close ( N ormal logi c) or open (Fail- safe logic).

If an a larm is act ivated an d the rea ding drops bel ow th e alarm setp oint, th e alarm i s 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 wi ll activat e when the parti cu late reading falls BELOW the setpoint. See Menu 1 Setu p d etails.

Particu late Monitoring Sy s tems Installation & Operating Manual

6.2 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 setpoin t ranges. Features designated with an asterisk (*) ar e optional. Operation of optional features is dependant upon model and options selected at the time of order. The following setup menus ar e based on firmware vers ion 2.2 7 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 t o the main sc reen without saving the current parameter’ s v alue.

Menu Item Range D e finitio n

Alarm #1

Relay #1 Setpoint

Alarm #1

Relay #1

Delay

0-5000

1-600

Sec

The alarm setpoint is compared to the proc ess reading to determine al arm status. Relay #1 will close when alarm #1 is active and open when alarm #1 is cleared.

Number of seconds the reading must exc eed the alarm setpoint before alarm relay #1 contac t will close.

* Alarm #1

Relay #1

Logic

Alarm #2

Relay #2 Setpoint

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 .

0-5000

The alarm setpoint is compared to the proc ess

reading to determine al arm 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 exc eed the alarm setpoint before alarm relay #2 contac t 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 .

Particu late Monitoring Sy s tems Installation & Operating Manual

6.3 Menu 2 Setup

Navigation within Menu 2 is similar to that described in Menu 1. Featur es designated with an asterisk (*) are optional. Operation of option al features is dependant upon model an d 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 adj ust the sett ing to the desired value. Press the ENTER k ey to save the value and proceed t o the next set up screen. Press the SETUP/ESCAPE k ey to return to the mai n screen without saving the current parameter’ s v alue.

Item

Range Definition

Bar

Graph

Span

Automatic Linear Automatic Log 100,000 Log 10,000 Log 1,000 Log

100.0 Log 10,000 Linear 1,000 Linear

100.0 Linear

10.0 Linear

1.0 Linear

Allows the user to configure the f ul l-scale span of the bar graph readout. The user may select a fixed scale, or a auto-ranging scale where the unit will s el ect it’s own sc ale automatically. The user can select between a LINEAR or LOGARITHMIC scale. (Log scaling is recommended f or process e s with dynamic, spiking readings suc h as a baghouse or cartridge ty pe dust coll ect or.)

Lock

Keypad

No/Yes Locks the keypad to prevent unauthorized

modifications. Once locked, alarm lev els 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 poi nts and user-

adjustable parameters to their factory default values by selecting YES

* 4-20mA Minimum

Scale

* 4-20mA

Output

Span

0.0 Linear

0.1 – 10.0 Log

0 – 5,000 Linear 1 – 900,000 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.

Sets the 20mA value of the 4-20mA output. Linear span can be set to any value. Logarithmic span wi ll 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 devic e must have a unique address.

Particu late Monitoring Sy s tems Installation & Operating Manual

Fail-safe

Relay 1

Fail-safe

Relay 2

Process

Run

Relay

Enable

* Perform

Zero

Check

* Perform

Span

Check

No/Yes When set to “Yes”, inverts the alarm relay

logic. Relay is ON when NO alarm conditi on exists and is OFF when there IS an alarm condition. Relay is OFF when power is removed from the control unit.

No/Yes When set to “Yes”, inverts the alarm relay

logic. Relay is ON when NO alarm conditi on exists and is OFF when there IS an alarm condition. Relay is OFF when power is removed from the control unit.

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 t o Automated Self Checks section of the manual for details on use of this relay input.

No/Yes When set to “Yes”, triggers an automatic

zero check. Refer to Automatic Self Checks section of manual for full det ails.

No/Yes When set to “Yes”, triggers an automatic

span check. Refer to Automatic Self Checks section of manual for full det ails.

Particu late Monitoring Sy s tems Installation & Operating Manual

6.4 Menu 3 Setup

Navigation within Menu 3 is similar to that described in Menu’s 1 and 2. Features designa ted with an asterisk (*) are option al. Operation of optional featur es is dependant upon model and option s selected at the time of order. The following set up menu s are bas e d on firmware version 2.27 or high er.

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 t o adjust a setting to the desired value. Press the ENTER key to save the value and proceed to the next screen. Press the SETUP/ESCA PE key to return t o the main screen without savi ng the current param eter’s value.

Menu Item Range Definition

Signal

Filter

Frequency

* Units of

Measure

Auto-

Range

Delay

0.033 – 2.0 Hz

1111 pA

2222 mg

1 – 30

Sec

This parameter controls the low-pass filtering of the input signal. Setting the f requency lower gives a more stable output reading. Setting the f requency higher gives a more dynamic output reading. Signal filtering is applied to the numeric readout only unl ess bar graph/4-20mA filtering is ON (see setting below).

This parameter sets the displ ayed and out put uni ts of measure to be either pA or mg/m first requires correl ation testing and instrument scaling.

This parameter controls how long the bar graph readout must be at either extreme before it automat ical ly switc hes ranges. If the bar graph is switching ranges t oo oft en, t he auto-range delay shoul d be inc reased.

* Peak Hold

Time

0 – 60

Sec

This parameter sets the amount of time a rapidly occurring peak reading is displ ayed. Peak Hold is used for processes that are very dynamic wit h spiki ng readings.

* Bar Graph

4-20mA

Output

Filtering

Correlation

Values

MINIMUM

and

MAXIMUM

(EM 70)

Yes/No This parameter enables or disables filtering of the bar

graph and the optional 4-20mA output. The fil tering applied is the Signal Filt er Frequency parameter listed above. Filtering is enabled by selecting YES and disabled by selecting NO.

0 – 5000

pA1=0 pA2=5000 pA3=0 pA4=5000

These parameters are used to re-sc al e the output from pA to mg/m entered and equivalent Scaled min/max values (pA3 and pA4) are entered. The control unit will convert the Raw values to Scaled values automatic al ly . To rem ove all scaling, set Raw min=Scaled min and Raw max=Scaled max. Example: 0-5000pA = 0-4000mg/m pA1=0, pa2=5000, mg3=0, mg4=4000

. Raw min/max values (pA1 and pA2) are

. Conversion to mg/m

Particu late Monitoring Sy s tems Installation & Operating Manual

6.5 Long Term Averaging

The lon g ter m averagin g function provi d es a rolling average of the real-time r eadings over time.

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 ENTER key to toggle between the Real-Time displ ay and the Average displ ay.

Main

Screen

Real-Time Display

Average

Display

Units

Shown

pA Displays the real-t i me reading. Before display, the real-time

reading is process ed through a low-pass input signal filter which smoothes the reading. See t he low-pass “S ignal Filter Frequency” setup in the Menu 3 setup section.

ApA Displays a selectable rolling time average of the real-time

reading. The average period (in mi nutes) is adjustable through the average setup screen. The word “AV G” is quickly shown in place of the readout once every five sec onds, indicating that the dis pl ayed and out put reading is an average.

Description

Press the SETUP key from the MAIN AVERAGE screen to enter the AVERAGE setup s creen. Use the UP/DOWN arrow keys to adjust settings to the desired val ues. P ress the ENTER key t o save a value and proceed to next setup screen. Press the SETUP/ES CAPE key to return to the main average screen without s avi ng the current parameter’s value.

Menu Item Range Definition

Average

Period

Clear

Average

0-360

Min

YES/NO When YES is select ed and the ent er

Number of minutes the real-tim e reading is averaged to comput e the average reading.

key is pressed the averaging is cleared and the average reading is initi al iz ed to 0.

Particu late Monitoring Sy s tems Installation & Operating Manual

6.6 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 tran smitted as linear or multi-decade logarithmic output.

Two parameters determine the type of output signal. The “4-20mA Minimum Scale” parameter determin es the pA equivalent of the 4mA output. Setting this parameter to “0.0” enables the Linear scale. A value oth er than “0.0” ini tiates Loga rithmic scale. Th e “4-20mA Output Span ” paramet er determines the pA equivalent of th e 20 mA output.

The 4-20mA analog output represents the linear or logarithmic equivalent of the “pA” particulate levels. Once the ana log output has be en transm itted to the PLC o r cha rt 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 follo wing two examp les show the formulas used to convert the 4-20mA sign al into pA.

4-20mA Linear Output

Linear out put is sel ected when the “4 -20m A Out put Min imum Scale” is s et to “0.0 ” pA. To con vert 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 pA

4 0.0 5 62.5 6 125.0 7 187.5 8 250.0

9 312.5 10 375.0 11 437.5 12 500.0 13 562.5 14 625.0 15 687.5 16 750.0 17 812.5 18 875.0 19 937.5 20 1000.0

Particu late Monitoring Sy s tems 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 prop er log(1 0 ) argument:

Y = Number_Of_Decades * (mA – 4.00) / 16

3. Convert log(10) argument to pA:

pA = 10^(Y) * (4-20mA Minimu m_Scale)

Example #1: See Menu #2 for d etails.

Where: 4-20mA Minimum Scal e = 0.1pA

4-20mA Output Span = 1000pA

Number_Of_Decades = Log (1000 / 0.1) = 4

4-20mA Output Y pA

4 0 0.1 5 0.25 0.2 6 0.5 0.3 7 0.75 0.6 8 1 1.0

9 1.25 1.8 10 1.5 3.2 11 1.75 5.6 12 2 10.0 13 2.25 17.8 14 2.5 31.6 15 2.75 56.2 16 3 100.0 17 3.25 177.8 18 3.5 316.2 19 3.75 562.3 20 4 1000.0

Particu late Monitoring Sy s tems Installation & Operating Manual

Example #2: See Menu #2 for d etails.

Where: 4-20mA Output M inimum Scale = 0.5pA

4-20mA Output Span = 500pA

Number_Of_Decades = Log (500 / 0.5) = 3

4-20mA Output Y pA

4 0.00 0.5 5 0.19 0.8 6 0.38 1.2 7 0.56 1.8 8 0.75 2.8

9 0.94 4.3 10 1.13 6.7 11 1.31 10.3 12 1.50 15.8 13 1.69 24.3 14 1.88 37.5 15 2.06 57.7 16 2.25 88.9 17 2.44 136.9 18 2.63 210.8 19 2.81 324.7 20 3.00 500.0

6.7 Interpreting Particulate Readings for Fabric Filter Applications

Particulate flow is very dynamic in natur e, thus the output signal is also usually very dynamic. This is more often the case with fabr ic 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 log arithmic ou tput (lin ear ou tput is also ea sily selected using the k eypa d ).

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 wh ile 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. Man y 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 condition s, high differ ential pressure or a lack of a filter cake buildup.

Particu late Monitoring Sy s tems Installation & Operating Manual

PARTICULATE READING GUIDE FO R FABRIC FILTERS

IMPORTANT

• The guide below is only an approximate guide for modern, highly-efficien t baghouses

• With large r or old er bagh ouses, readings can be significantly higher than t he ran ges shown below

• Shaker and reverse air baghouses will have higher peak readings as compared to pulse jet

• Readings tend to be higher when new filter s are installed and a filter cake h as yet to form

• With sm all cartrid ge filters, th e r eadings tend to be a t the lower en d of the ranges

• Readings tend to also be lower with highly-efficien t filter media such as Gor e-Tex® fabric (Gore-

Tex is a reg istered tr ademark of W.L. G ore & Associat es .)

•

Typical Readings and Guide for New Efficient Fabric Filters

AVERAGE

BASELINE READINGS

PEAK READINGS

(after cleaning cycle)

FILTER CONDITION

1 – 10 pA Less than 50pA No significant emissions

10 – 100 pA Less than 500pA On set of emissions

100 – 1000pA Gr eater than 500pA Significant emissions present

_ ALARM LEVELS FOR EPA COMPLIANT LEAK DETECTION

IMPORTANT

• Alarm levels for EPA compliant leak detection such as MACT regulations should initially be set as

low as possible unt il sufficien t trend data has been logged and all considerations have been made.

• Do not in crease th e alarm levels without pr oper justification.

• Documentation of properly determined alarm levels is recommended as well as locking out alarm

set point adjustment except to authorized personnel.

• Consu lt factor y for alarm set point as sistance an d or FilterWare Visualization and EPA Compliance

Software for advanced alarming and alarm record keeping.

Particu late Monitoring Sy s tems Installation & Operating Manual

6.8 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 al ar m should be set based on the average base line reading and another alarm should set ba s ed on the pea k r eadings foll o wi ng cleanin g cycl es .

Normal ly, Al arm # 1 is used for det ectin g su stain ed incr eases in th e base lin e rea ding . For ex ampl e a baghouse that has new, highly-efficient filters may h ave an average baseline reading of 10-20pA. It would then be recommend to set the baselin e alarm at 30-50pA with an alarm delay time that was long en ough so th at cl ean ing cycle pea ks di d n ot act i vat e the basel i n e alar m . Ea ch a p pli cati on ca n be different (for exampl e much hi gher readings are possible with larger, older bagh ous es) 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 tr end and data log the readings over time before finalizing the settings. Correlations to stack test data can also be incor p orated to correlate the ou tput to actu al mass concentration to set more quantitative al arms.

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 por ous, the momentary puffs of particulate emissions that normally occur just after a cleaning cycle will increase in peak heigh t and duration (peak width). Essentially the cleaning cycle amplifies the existen ce of small tears. Thus, setting an alarm to detect changes in the peak emissions is often referred to as a Pr e-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 th e filters should be changed immediately. Wh ere as, when only the peak emissions have increased, emission will likely not be visible and there likely would be time to schedule ch anging the filters (i.e. early warning).

Telephone or on-site assistance is available to provide suggestions in setting alarm levels.

Particu late Monitoring Sy s tems Installation & Operating Manual

7. Manual System Zero Check

The S ystem Zer o Check is us ed at in stall ati on to confi rm prop er in stal lati on and for tr oublesh ootin g. This check is mostly for control units that are not equipped with the optional self check subs ystem.

SAFETY

• Always disconnect power to the control unit before making any wiring

changes at eith er the control unit or sensor as well as when making any mount ing changes or replacing any component.

• Do not remove the sensor (even when power is disconnected) from a

running process if it will in any wa y compromise personnel or plant safety.

• All regulatory and plant safety procedures must be followed at all times

whil e p er forming any equipment ch eck or maintenance.

• For hazardous area sensors, do not disconnect the external earth ground

strap.

• Do not perform any pr ocedure if it will in any way compromise hazardous

area procedures .

SYSTEM ZERO CHECK

1. Shut the process off, stop p ing flow complete ly, including all ai rf low 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 con trol units specified minimum

detection level. If the system passes this ch eck th en it is assured that there are no false signals entering the system.

If th e system z er o ch eck is not s uccess ful , each comp on ent of th e system sh oul d be checked individ u ally, in the fol lowing or d er :

1. Control Unit Zero Ch eck

2. Coaxi al Cable Zero Check

3. Sensor Zero Check

Particu late Monitoring Sy s tems Installation & Operating Manual

CONTROL UNIT ZERO CHECK

1. Disconnect power to the control unit.

2. Open th e en cl osure co ver an d uns cr ew the coa xi al cabl e con n ector from th e

contr ol unit. Leave the connector inside the control unit en closure. Make sure th e con nector d oes n ot s lip down into the conduit.

3. Close the control un it enclosur e cov er.

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 con trol units specified minimum

detection level. If the control unit passes this check, there are no false signals entering th e control unit.

PASS:

1. Discon nect power from the control unit.

2. Open th e enclosu re cover and re-a ttach th e coaxial ca ble conn ector to th e

control unit.

3. Close the enclosure cover and proceed to th e Coaxial Cable Zer o C heck.

FAIL:

1. If a zer o r eadin g cann ot be obt ain ed, cl ose th e encl osur e cover an d con tact

the factory for fur ther assistance.

COAXIAL CABLE ZERO CHECK

1. Disconnect power to the control unit.

2. Open the sensor enclosure cover and disconnect the coaxial cable center

conduct or from th e sensor pr obe end. Do n ot disconn ect the coaxia l cable shi eld. Do not r emove the probe fr om the pr ocess. Lea ve the coaxi al cabl e 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 con trol units specified minimum

detecti on l evel. If t h e coax ial ca ble pa sses th is ch eck th en ther e ar e no fal se 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 s e nsor probe en d.

3. Close the sensor enclosure cover and proceed t o the sensor zero check.

FAIL:

1. Check cable insta llation and routing in struction s in the Instal lation s ection

of this manual for proper cable installation. Make any changes necessary.

2. Cont act the factor y for fu rther ass istance.

Particu late Monitoring Sy s tems Installation & Operating Manual

Once th e contr ol unit an d coaxial cable zer o have been checked, p roceed to t he Sen sor Zero Ch eck. To per form the sen sor zer o check the proc ess flo w must be stoppe d or a sensor test pip e (avai labl e 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 el ectrical sh ield for the pr obe wh ile it is out of th e process.

SENSOR ZERO CHECK

1. Do not remove the sensor from a running process if it will in any way

compr om ise personn el, plant sa fety or hazard ou s area safety procedures .

2. Disconnect power to the control unit.

3. Remove t he sensor from th e process and insert it into the gr ounded m etal

test p ipe. For hazardous area sen sors do n ot disconn ect the ext ernal sensor eart h 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 con trol 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 hazardou s area sensor s do not d isconnect th e external sen sor gr ound strap.

FAIL:

1. Cont act the factor y for fu rther ass istance.

When p erforming a zero check, keep in min d th at it may be acceptable t o c onsider a small fal s e 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.

Particu late Monitoring Sy s tems Installation & Operating Manual

8. Automatic Self Checks

An optional self check subsystem is available to automatically verify calibration and proper operation of the electroni cs, sensor and cable. Self checks can be performed while the system is online and monitoring particulate. No external test equipment or operator intervention is requir ed to activate or complete the self check routines. Any errors detected by t he self checks are r eported through the display, 4-20mA, relay and Modbus® outputs. The following automatic self checks are per formed:

• Contr o l Uni t Hard ware C heck

• 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 Qua lity 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 Contr ol Unit Hard ware Ch eck is an automat ic check of all major electrica l compon ents in the control unit. This check is automatically performed each time power is applied to the control unit.

Check Description

Watchdo g Timer

SRAM Checks the integrity of the SRAM memory.

Non-Volatile

Memory

Option Board

Analog Converter

Calibration

Monitors all program tasks running in the microprocessor and automatically resets the processor in the event of lock-up.

Checks the integrity of the Non-Volatile memory. The results of this check produce a check su m value whi ch is an alyzed each time a nonvolatile memor y write occurs.

Checks for proper installation of Power Supply, RS-485 and Self Ch e ck option boards.

Check s calibrat ion of the 22 bit hi gh resoluti on an alog converter.

Particu late Monitoring Sy s tems Installation & Operating Manual

8.2 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 discon nect of th e par ticulat e sen s or cable

2. Allow th e reading to stabilize

3. Measure the reading and compare to the allowabl e zero toler ance

4. Electronic re- con nect of the par ticulat e sensor cable and resume normal operati on .

There are four independent methods to acti va te the zero ch eck :

Method Description

Power-Up

Keypad

Automatic

Remote

A zero check is automatically performed each time power is applied to the con trol unit

The operator may activate a zero check manua ll y th rough the control unit keypad. Reference Menu #2 setup tree for complete details.

The con trol unit may be configured to automatically per form 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 meth od.

Automatic self ch eck s may be activated at preset hourly, daily and monthly dates/times when connected to a computer running the FilterWare Visualization application.

The operator may activate a zero check manually when connected to a remote computer running th e FilterWare Visualization application . Alternately, self checks may be independently activated from any remote PC or PLC with Modbus® communication capability.

Particu late Monitoring Sy s tems Installation & Operating Manual

8.3 Control Unit Span Check

The Span Check will verify the in strument span calibration. The internal self check subsystem will automatically perform the following procedure:

1. Electronic discon nect of th e par ticulat e sen s or cable

2. Electronic inp ut of a calibrated p A reference signal

3. Allow th e reading to stabilize

4. Measure the reading and compare to the allowabl e s p an toleran ce

5. Electronic discon nect of th e r eference si gnal

6. Electronic re- con nect of the par ticulat e sensor cable and resume normal operati on .

There are four independent methods to acti va te the span check :

Method Description

Power-Up

Keypad

Automatic

Remote

A span check is automatically performed each time power is applied to the control unit

The operator may activate a span check manually through th e control unit keypad. Reference Menu #2 setup tree for complete details.

The con trol unit may be configured to automatically per form 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 meth od.

Automatic self ch eck s may be activated at preset hourly, daily and monthly dates/times when connected to a computer running the FilterWare Visualization application.

The operator may activate a span check manual ly when connect ed to a remote computer running th e FilterWare Visualization application . Alternately, self checks may be independently activated from any remote PC or PLC with Modbus® communication capability.

8.4 Sensor Cable Check

Integrity of th e s ensor cable i s ch eck ed using ad vanced dig ital signal processin g algorithm s. Th e cable check oper at es con tinuou sly an d does n ot int erfere wi th nor mal m onitor ing of th e pr ocess par ticu late signal. The sensor cable check i s disabled whi le zero or span ch eck s are being per formed.

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 ch eck operates continuously an d does not interfere with normal monit oring of the pr ocess parti culate si gnal. The par ticulate sen sor check is d isabled whi le zero or span ch ecks are being performed.

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8.6 Process Running Signal

A process running signal in dicates to th e control un it wheth er the main pr ocess fan i s 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 fu r ther details.

2. Automatic system zero – veri fi es zero of the tot al system el ectronics, cable and s ensor while fu l ly

inst alled in the process.

For proper operation the following conditions must be met:

1. A process runnin g signal must be conn ected t o the contr ol unit process ru n relay in put chan nel.

This signal must be pr ovided from an isolated, non-powere d relay con tact that cl oses when th e main process fan is on, and opens wh en the main pr ocess fan is off. A motor starter auxiliary contact an d/or separate con trol relay ar e 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 pr ocess r un relay in put chann el mu st be en abled for u se. Ref eren ce men u # 2 setu p tree f or

complete details.

8.7 Monitoring Self Check Status

There are four independent methods to monit or the status of the self check s u bsystem.

LCD Display

The con trol unit’s LCD display will indicate the current status of the self check subsystem as listed below:

PV Units Display Indication

‘pA’ or ‘m g’ No self checks currently runn ing. The most r ecent self check s were

successful, no failures ‘SC1’ Zero ch eck in process ‘SC2’ Span ch eck 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 ch eck is perfor med success fully, or power to the con trol unit is disconnected. Alarm relay #1 will be activated in the event of a self check failure by default. Alarm output relays may be configur ed to operate in normal or fail-sa fe m od es.

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 sp an ch eck in process, s ensor is disconnect ed

3.6mA A self check er ror has occurred

Serial or Ethernet Communication Network

All information regarding status, control and setup of the self check subsystem is accessible as regi s ter data through the contr ol unit’s communication networ k. See the Modbus® register map at the end of this documen t 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 perfor med. When a self check i s com p leted, all particulat e alarms will r es u me normal operation.

8.9 Self check Recording

EPA MACT regulations require that plants maintain a recor d 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 sp ecifi c, n on-stan dard , mA levels a nd tr ansmi t stat us infor mation to a cen tral plant in format ion network for record storage.

Serial or Ethernet Communication Network

The over all stat us of each self ch eck, a s well a s the r esult s of th e most r ecent sel f check s per formed , are acces sible t hrough the Modbus® network p ort. Thi s informa tion may be monit ored and log ged 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 pr imarily used when troubleshooting a system without the option al automatic self checks. When tr oublesh ootin g, consi der each componen t of th e system: T he contr ol unit , th e sensor coax cabl e and the sensor assembl y.

False High Signals (False Alarms)

1. When an appar ent false h igh sign al is pr esent, fir st check t he process t o be sur e the par ticulat e

level has not increased. Keep in mind that the system can detect very low levels. In filtration appli cations th e system can det ect invisibl e particulat e levels an d very small emissions.

2. Check th e sen sor co ver a nd con dui t seal to be sur e th ey wer e not left op en a llowin g ra in t o 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 Al arm (When Believed Necessary)

1. Increase the p articulat e level or introduce particulate into t he air stream and monitor for a response.

If th e system respond s properly re-eva luate the selected alarm points an d the process con ditions.

2. If there is n o response, check for electr ical cont in u ity from the sensor to the con trol un it end of the coax cabl e.

3. Contact the factory for a Field Test Unit that can generate a sign al to check resp onse and calibration.

10. Ro utine Maintenance

EQUIPMENT MAINTENANCE

• Only appropriately licensed profession als shou ld perfor m main tenance on

this pro d u ct.

• For operator safety and to prevent ignition of flammable or combustible

atmospher es always disconnect power before servicing.

Particulat e Sensor: There i s no electr onic ca librat ion or zer o adjustm ent for th e sens or. The sen sor does n ot norm ally need a ny clea ning and for op timal perform ance, r outine cl eanin g of the sen sor i s not reco mmended.

Control Unit: The viewing window, keypad and enclosure may be cleaned with soap and wa ter as needed. Use a soft cloth to prevent scratching the window. Do not use an abrasive pad or any chemicals that wi l l attack pla s tic or Lexan.

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11. Spare Part s

Item Details Mfr Part No.

Line Fuse, 115/230VAC 0.032A 250V Slo-Blo type ‘T’

0.050A 250V Slo-Blo type ‘T’ when Self Check Option is installed

Line Fuse, 24VDC 0.250A 250V Slo-Blo type ‘T’ 218.250 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 CCA-Feet

LittleFuse

218.032

LittleFuse

218.050

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12. Appendix

Modbus®/RTU RS-485 Networking Protoco l

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 a t the sam e time) . Serial ba ud rate is fixed at 19, 200 bps. Th e serial fr ame is fi xed at 8 data bits, 1 stop bit and no parity. Communications are supported over a maximum network length of 4000 feet. When connect ing more th an two devices on the net work, all devices shoul d be wired ‘in-lin e’ and n ot in a ‘star’ confi g uration.

A terminating resistor must be present at each end of the RS-485 networ k to eliminate transmission reflections on the serial lin e. Some con trol units con tain 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 un its that d o not cont ain a terminat ing jumper, a 120ohm ½ watt resi stor may be placed across the RS-485 +/- out put terminals.

PLC Connection

Connection to p lant PLC’s is dependant upon the communi cations ports avai lable on th e specific PLC being used. Ensur e 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® RT U 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 w ith the RS -485 port, the Mo dbus ®/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 con verter the converter must be setup so it will transmit when the TD lin e is asserted.

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Personal Compute r Connection

Connection to a personal computer is made to the RS-232 COM port with the addition of a converter modul e. Converter modules are availa bl e from the factory. The converter mod u le modifies the voltag e 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 supplyin g 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 th e network devices and softwar e is simple. The user has no need to know th e speci fics of t he Modbu s® pr otocol or the t ypes of m essages sent and r eceived. Al l of th e low-lev el c om mu ni cati on s fun ct i ons ar e t a ken ca r e of a n d ar e tr an spar ent t o th e syst em user . Th e PC running our software is configur ed as the networ k master and all other devices on the networ k are configu red 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 confir min g th e act i on tak en, an y dat a to be r etur n ed, and an err or -check in g fi eld . If a n err or occu rr ed in receipt of the message, or if the slave is unable to perform the requested action, the slave will constru ct an error m essa g e and sen d it as its r esponse.

Three data types ar e supported: Discrete (1-bit) Integers (16-bit) IEEE Floating point (32- bit)

Modbus® Protocol Function Codes

Code Function Description

01 Read Coil Status Reads digital outputs or 1 bit data registers 02 Read Input Status Reads digital inputs or 1 bit data registers 03 Read Holding Register Reads analog outputs or 16 bit data registers 04 Read Input Register Reads analog inputs or 16 bi t data registers 05 Force Single Coil Writes digital outputs or 1 bit data registers 06 Preset S ingle Regist er Writes an alog output or 1 6 bi t d ata regist er 07 Read Exception Status Reads status information 15 Force Multiple Coils Writes digital outputs or 1 bit data registers 16 Preset M u ltiple Registers Writes analog outputs or 16 bit data r eg isters 17 Report Slave ID Reads device type information

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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 Runnin g) 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 t o Activate (0=None, 1=Relay 1, 2=Relay 2) 43382 Zero Check Relay to Activate (0=None, 1=Rel ay 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=Non e, 1=Relay 1, 2=Relay 2) 43399 Zero Check Allowable Tolerance (pA) 43404 Span Check Allowable Tolerance (pA) 43409 Full System Zero Check Allowa ble Tolerance (pA) 43401 Zero Check Settling Time (milliseconds) 43406 Span Check Settling Time (milliseconds) 42402 Result Measured fr om Last Zero Check (pA) 42407 Result Measured fr om Last Span Check (pA) 42412 Result Measured fr om Last Full System Zero Check (pA)

Modbus®/RTU Registe r s

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 Integer Integer Integer Integer

Float

Float Integer Integer

Float

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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 tog ether and filters network traffic. Devices must be connected directly to a switch using a standard Category 5e Ethernet cable, or directl y t o another Eth ernet device usi ng a crosso ver Ca tegory 5e Eth ernet cable. Th e 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 a ut o-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 suppl ied as an ext ern al con ver t er hou sed in a separ at e en cl osur e du e to th e li mit ed space wit hin 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 a pp ears as an ordin ary Ethernet/IP® device on the Ethernet network.

Network Protocol Description

Ethernet/IP® is an open n etworki ng protocol gover ned by t he Ope n DeviceNet Vendor As s oc iation (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 requ iring communicati ons on an Ethernet/I P ® network ar e 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 occurr ing.

For complete details on th e 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 an d beyond IP address and Su bnet 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 belo w:

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Network Addressi ng 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 E thern et/IP® module is fixed and is listed on th e enclosure.

The IP address is set to a factory default value of 192.168.0.254 with subn et mask 255.255.255.0 when shipped. To change the I P ad dress a BOOTP s erver must be present on the Ethern et network. The foll o wing procedure is used to change the IP ad dress:

1. The Ethern et/IP® module must be unlocked to allow changes to its in ternal 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 Class Instance Attribute Data

0x45 0x67 0x89 0xAB 0xCD

2. BOOTP operation within the module must be ENABLED. By default BOOTP operation is

disa bl ed . After the IP address has been set BOOTP opera tion must be set ba ck 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 configur e it with the MAC ad dress of the modu le

and the desired new IP address and Subnet mask.

4. Cycle power to the module. Once power is re-applied the module will broadcast a BOOTP

request for an IP address. Th e BOOTP server should resp ond b y assign ing the desired IP address to the module.

5. Unlock the module again to allow ch anges to the configuration. To toggle the lock state the

followin g explicit message must be sent to the module:

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Service Class Instance Attribute Data

0x45 0x67 0x89 0xAB 0xCD

6. BOOTP operati on within the module m u st be DISABLED. To DISABLE BOOTP opera t ion

the following explicit message must be sent to the module:

Service Class Instance Attribute Data

0x10 0x64 0x01 0x6E 0x00

7. Cycle power to the module. Once power is re-applied the module will come online with the

new I P addres s a nd Subnet mas k. BOOTP opera t ion should be disable d at this point so no BOOTP requests wi ll be issued by the module.

8. A network p i ng shou ld be used to verify th at the IP address and Subnet mask have be en 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 bi t unsigned integer analog data Sin t – 16 bit s igned analog data Float – 32 bi t signe d floating p oint analog data

Float ing point va lues are r epresen ted in IEEE format (32 -bit) wh ere the 1 word and the 2

Input (T->O) Assembly Object (Class 0x04, Instance 0x65) Siz e 13 (16 bit words)

16-Bit

Word

Modbus®

Range Range Units Data

Type

Description

Address Address Min Max

0 - 0 65535 Usint Network status (0=ok, >0=error)

1 - 0 65535 Usint Alarm status 1-16 (1 = alarm, 0 = ok) 1:0 03073 0 1 Bool Alarm status – Max alarm #1 (1=ON, 0=OFF) 1:1 03074 0 1 Bool Alarm status – Pr e-Visible alarm #2 (1=ON, 0=OFF)

2 - 0 65535 Usint Self check status information 2:0 03247 0 1 Bool Zero check status (1= RUNNING, 0=NOT RUNNING) 2:1 03248 0 1 Bool Span check status (1=RUNNING, 0=NOT RUNNING) 2:2 03249 0 1 Bool Full system zero ch eck status (1=RUNNING, 0=NOT

RUNNING)

2:3 - 0 1 Bool Not Used 2:4 03251 0 1 Bool Zero check remote activate (1=ACTIVATED, 0=NOT

ACTIVATED)

2:5 03252 0 1 Bool Span check remote activate (1=ACTIVATE D, 0=NOT

ACTIVATED)

2:6 - 0 1 Bool Not Used 2:7 03254 0 1 Bool Probe and cable check status (1=ERROR, 0=OK) 2:8 03255 0 1 Bool Zero check status (1= ERROR, 0=OK) 2:9 03256 0 1 Bool Span check status (1=ERROR, 0=OK)

2:10 03257 0 1 Bool Full system zero ch eck status (1=ERROR, 0=OK)

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2:11

Thru

- 0 1 Bool Not Used

2:15

3 40609 Particulate process variable LO word

4 40610

5 40611 Averaged particulate process variable LO word

6 40612

7 40737 Alarm level – Max alarm #1 LO word

8 40738

9 40739 Alarm level – Pre-visible alarm #2 LO word

10 40740

0 5000 pA Float

Par ticul ate proce s s variable HI word

0 5000 pA Float

Averag ed particu late process va riable HI wor d

0 5000 pA Float

Alarm level – Max alarm #1 HI word

0 5000 pA Float

Alarm level – P re-visibl e alarm #2 HI word 11 40769 0 600 Usint Alarm delay – Max alarm #1 12 40770 0 600 Usint Alarm delay – Pre-visible alarm #2

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 un it). The first word in the map contains th e run/idle bit (bit 0). The run/idle bit controls write access to the control unit. Wh en the run/idle bit is set to 0 the con trol unit is set to idle mode. In idle mode, th e Ethernet/IP® server will allow read on ly 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 con trol un it. The r un/i dle contr ol 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 bi t unsigned integer analog data Sin t – 16 bit s igned analog data Float – 32 bi t signe d floating p oint analog data

Float ing point va lues are r epresen ted in IEEE format (32 -bit) wh ere the 1 word and the 2

Output (O->T) Assembly Object (Class 0x04, Instance 0x66) Size 7 (16 bit words)

16-Bit

Word

Modbus® Range Range Units Data

Type

Description

Address Address Min Max

0 - 0 1 Usint Run/Idle mode setting (0=idle/read only, 1=r un/read write) 1 40737 Alarm level – Max alarm #1 LO word 2 40738 3 40739 Alarm level – Pre-visible alarm #2 LO word 4 40740

0 5000 pA Float

Alarm level – Max alarm #1 HI word

0 5000 pA Float

Alarm level – P re-visibl e alarm #2 HI word 5 40769 0 600 Sec Usint Alarm Delay HI Particulate 6 40770 0 600 Sec Usint Alarm Delay HI Delta P

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Configuration Assembly Object (Class 0x04, Instance 0x80)

The configuration assembly object is not implemented. However, some Ethernet/IP® clients requ ire one. If this is the case, use In stance ID 0x80 wi th a da ta length of 0.

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Notes:

Dwyer DPM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual