ABLE Ultima OPIR-5 Installation & Maintenance Instructions Manual
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ABLE Ultima OPIR-5 Installation & Maintenance Instructions Manual

Infrared open path detector for hydrocarbon gas applications
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Installation & Maintenance Instructions
Ultima® OPIR-5
Infrared Open Path Detector for Hydrocarbon Gas Applications
Registered Address
ABLE Instruments & Controls Ltd
Cutbush Park, Danehill, Lower Earley,
Reading, Berkshire, RG6 4UT. UK.
Reading
Tel: +44 (0)118 9311188 | Email: info@able.co.uk
Aberdeen
Tel: +44 (0)1224 725999 | Email: ab@able.co.uk
Web
able.co.uk
E-commerce
247able.com

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  • Page 1 Installation & Maintenance Instructions Ultima® OPIR-5 Infrared Open Path Detector for Hydrocarbon Gas Applications Registered Address Reading Tel: +44 (0)118 9311188 | Email: info@able.co.uk able.co.uk ABLE Instruments & Controls Ltd Cutbush Park, Danehill, Lower Earley, Aberdeen E-commerce Reading, Berkshire, RG6 4UT. UK.

  • Page 2: Ultima® Opir-5

    Ultima® OPIR-5 Infrared Open Path Detector for Hydrocarbon Gas Applications The information and technical data disclosed in this document may be used and disseminated only for the purposes and to the extent specifically authorized in writing by MSA. Instruction Manual 06-14 MSA reserves the right to change published specifications and designs without prior notice.
  • Page 3 Ultima OPIR-5 Detector This page intentionally left blank...

  • Page 4: Table Of Contents

    Rapid and Massive Liquid Propane Releases............18     3.8.2 Solutions to Guard against These Situations ............. 18     4.0 OPERATION ......................... 19  Using the Ultima OPIR-5 Detector Menus ................19     Menu Options .......................... 21     Test “---” ........................... 21  ...
  • Page 5 Ultima OPIR-5 Detector Setup “SE” ..........................21     4.4.1 Setup Options Sheet ....................23     Flash Input “in” ......................... 24     Alignment/Adjustment “AJ” ...................... 24     Finish “Fi” ..........................24     Maintenance ..........................24  ...
  • Page 6 Ultima OPIR-5 Detector 7.3.1 Spare Parts ......................... 36     7.3.2 Accessories ........................ 36     Engineering Documentation ....................37     8.0 APPENDIX A ........................38  Split-Range Analog Output Option ..................38    ...
  • Page 7 Figure 4: Outline and Dimensional Drawing ....................9   Figure 5: Installing onto the Mounting Arm ....................10   Figure 6: Ultima OPIR-5 Source with Attenuator (P/N 329113-1) .............. 11   Figure 7: Source Wiring ..........................12   Figure 8: Receiver Wiring .......................... 12  ...

  • Page 8: Quick Start Guide

    Quick Start Guide System Mounting The Ultima OPIR-5 Detectors are shipped with either mounting assembly shown below. After the mounting location has been established, mount the support arm/base. Attach a pan-tilt assembly to each unit. Apply lithium grease on each taper joint before attaching a unit to a support arm/base.

  • Page 9: Conduit Sealing

    Ultima OPIR-5 Detector Conduit Sealing Each conduit run from a hazardous to a non-hazardous location should be sealed so that gas or flames cannot pass from one electrical installation to another through the conduit system. A conduit seal must also be installed within 18 inches of the Source and Receiver enclosure if installed in a Division 1 location.

  • Page 10: Terminal Connections

    Ultima OPIR-5 Detector Terminal Connections To make the wiring connections to the Ultima OPIR-5 Detector, loosen the retaining screw on the cover of each unit using the supplied hex wrench and unscrew the rear cover. All output connections are made inside the housing (see figures on following page for terminal block locations).
  • Page 11 Ultima OPIR-5 Detector MOD1- Modbus1- Modbus2- MOD2- MOD1+ Modbus1+ Modbus2+ MOD2+ Normally Normally Normally Normally Energized Energized energized energized Alarm NO Alarm NC Fault NO Fault NO FLT1 Alarm C Alarm C Fault C Fault C FLTC Alarm NC Alarm NO...
  • Page 12 2.5 mm ) wire. Primary DC voltage power must be provided by the customer. Since the Ultima OPIR-5 Detector is designed to continuously monitor for leaks of combustible gas, a power switch is not included to prevent accidental system shutdown. Power must remain disconnected until...
  • Page 13 SU (Start Up) 0 (Gas Concentration) Continuous The Ultima OPIR-5 Detector contains a heater circuit to remove condensation from the windows. The unit should be allowed to stabilize for approximately two hours before continuing with the setup mode. The resolution of the display is the either 0.1 LEL ●...
  • Page 14 Ensure that there is no significant amount of background gas when the unit is setting the zero value, as this will alter the Ultima OPIR-5 Detector performance. If there is gas present, try setting-up the Ultima OPIR-5 Detector on a breezy day, as this dissipates the gas.
  • Page 15 Response Test After initial alignment, a test of the Ultima OPIR-5 Detector should be carried out using the test gas films for methane or propane (part numbers 329083-1 or 329084-1, respectively).

  • Page 16: Introduction

    Remember these products are for your safety. Special Warnings The Ultima OPIR-5 Detector contains components which can be damaged by static electricity. Special care must be taken when wiring the system to ensure that only the connection points are touched.

  • Page 17: Features And Benefits

    Power supply input reversal protection: protection against miswiring damage.  Dirty Window delay and Beam Block delay: reduces maintenance and false alarms. Applications This is a partial list of applications suitable for the Ultima OPIR-5 Detector:  Compressor stations  Drilling and production platforms ...

  • Page 18: System Integrity Verification

    Ultima OPIR-5 Detector System Integrity Verification Commissioning Safety Systems Before power up, verify wiring, terminal connections and stability of mounting for all integral safety equipment including, but not limited to:  Power supplies  Control modules  Field detection devices ...

  • Page 19: Product Description

    NOTE: Extremely dense fog, steam or interruption of the beam by an object or person may cause a system fault 2.1.3 Measurement Scale With the Ultima OPIR-5 Detector, as there is no fixed path length, the reading is reported concentration meter.

  • Page 20: Figure 2: Indoor Gas Cloud

    (highly sensitive to low levels of hydrocarbons) and the LEL•meter range (large hazardous levels of hydrocarbons). The Ultima OPIR-5 Detector display is auto-ranging. In general, an open path monitor can give similar responses to large, low concentration gas clouds and small, high concentration gas clouds as shown below.

  • Page 21: Typical System Gas Cloud Measurements

    Readings of Methane Gas Clouds 0-5 LEL•meter Range 2.1.5 Control Electronics Both the Ultima OPIR-5 Detector Source and Receiver units operate from a 24 VDC input. This unregulated 24 VDC is fed to on-board power supplies that produce all necessary...
  • Page 22 Ultima OPIR-5 Detector In normal operation, the microprocessor program constantly monitors the two infrared wavelengths and performs mathematical operations on this information in conjunction with values obtained during the factory calibration process. The microprocessor derives output information and feeds it to the digital to analog converter to produce two 4 to 20 milliampere (mA) signals that are proportional to the 0 to 5,000 ppm•meter and 0 to 5 LEL•meter for the methane sensing unit and 0 to 2,000 ppm•meter and...

  • Page 23: Installation

    Ultima OPIR-5 Detector 3.0 Installation Receipt of Equipment Original shipping containers should be kept for future shipping or storage needs. Shipping container contents should be carefully removed and checked against the packing list. If any damage has occurred or there is any discrepancy in the order, please notify MSA as soon as possible.

  • Page 24: System Mounting

    Ultima OPIR-5 Detector System Mounting The Ultima OPIR-5 Detectors are shipped with either mounting assembly shown in Figure 4. After the mounting location has been established, mount the support arm/base. Attach a pan- tilt assembly to each unit. Apply lithium grease on each taper joint before attaching a unit to a support arm/base.

  • Page 25: Installation

    Ultima OPIR-5 Detector Installation If necessary, remove the pan-tilt assembly from the arm. To do so, unscrew the 24 mm nut from the bottom of the pan-tilt. Remove the lock washer and flat washer. Put the washers and the nut in a secure place.

  • Page 26: Conduit Sealing

    Terminal Connections To make the wiring connections to the Ultima OPIR-5 Detector, loosen the retaining screw on the cover of each unit using the supplied hex wrench and unscrew the rear cover. All output connections are made inside the housing (see figures on following page for terminal block locations).

  • Page 27: Figure 7: Source Wiring

    Ultima OPIR-5 Detector Figure 7: Source Wiring Figure 8: Receiver Wiring...

  • Page 28: Table 3: Receiver Wiring Terminal Locations

    Ultima OPIR-5 Detector MOD1- Modbus1- Modbus2- MOD2- MOD1+ Modbus1+ Modbus2+ MOD2+ Normally Normally Normally Normally Energized Energized energized energized Alarm NO Alarm NC Fault NO Fault NO FLT1 Alarm C Alarm C Fault C Fault C FLTC Alarm NC Alarm NO...

  • Page 29: Terminal Block Operation

    2.5 mm ) wire. Primary DC voltage power must be provided by the customer. Since the Ultima OPIR-5 Detector is designed to continuously monitor for leaks of combustible gas, a power switch is not included to prevent accidental system shutdown. Power must remain disconnected until all other wiring connections are made.

  • Page 30: Applying Power And Alignment

     Verify that the signal wiring is correct.  Verify that the power supply is connected properly. The Ultima OPIR-5 Detector is powered by +24 VDC.  Make sure the cover is securely installed or the area has been declassified.

  • Page 31: Alignment And Adjustment

    Ensure that there is no significant amount of background gas when the unit is setting the zero value, as this will alter the Ultima OPIR-5 Detector’s performance. If there is gas present, try setting-up the Ultima OPIR-5 Detector on a breezy day, as this dissipates the gas.

  • Page 32: Response Test

    3.7.4 Response Test After initial alignment, a test of the Ultima OPIR-5 Detector should be carried out using the Test Gas Films for methane or propane (part numbers 329083-1 or 329084-1, respectively).

  • Page 33: Operational Cautions

    The ppm•m range of the Ultima OPIR-5 Detector should be used as a warning that there is a gas leak. This may allow action to take place before a leak reaches a hazardous level, while the LEL•m range should be used for a gas leak alarm.

  • Page 34: Operation

    Ultima OPIR-5 Detector 4.0 Operation The Ultima OPIR-5 Detector front panel includes an LED digital display, Alarm and Warning LEDs, and displays a set of menu options that provide the user with the most flexible detector system possible. In addition to the Ultima OPIR-5 Detector menu options for operations and configuration tasks, there is an extensive set of Modbus and HART commands for the same tasks that can be sent from remote Modbus and HART devices in control room areas.

  • Page 35: Figure 12: Ultima Opir-5 Detector Menu Tree

    IR5500 MENU LEGEND relay setpoint STATIC MENU OPTION FLASHING MENU OPTION HOLD MAGNET REMOVE MAGNET APPLY MAGNET TIMEOUT ##.# IF HART IS PRESENT IF HART IS NOT PRESENT ##.# Figure 12: Ultima OPIR-5 Detector Menu Tree...

  • Page 36: Menu Options

    Ultima OPIR-5 Detector Menu Options The Ultima OPIR-5 Detector allows the user to reset, test, and align the system as well as configure Receiver outputs. To access the menu, place the magnet supplied with the Ultima OPIR-5 Detector over the MSA logo on the label of the Receiver for approximately five seconds.
  • Page 37 LA or nL - Latching or Non-Latching. If this relay is set to “nL” (non-Latching), the Ultima OPIR-5 Detector must be connected to an auxiliary system which is able to provide the same function as a latching relay i.e. the alarm can only be reset manually.

  • Page 38: Setup Options Sheet

    Ultima OPIR-5 Detector 4.4.1 Setup Options Sheet SE - Apply Magnet when this code is showing to enter Setup. bb - Apply magnet when this code is showing to alter the options for Beam Block 5 to 60 - Select how many seconds before sending beam block fault...

  • Page 39: Flash Input "In

    Apply the magnet when “AJ” is showing and the unit will enter the Alignment/Adjustment Mode. This mode allows the user to re-align the Model Ultima OPIR-5 and set a new “zero” value. This mode is covered in Section 3.6. Finish “Fi”...

  • Page 40: Lel And Ppm Negative Drift Faults

    0 mA, prompting the detector to produce a fault. It is unsafe to use the Ultima OPIR-5 Detector when there is negative drift in the LEL range. A LEL negative drift causes both currents to go to zero and the fault relay to de-energize. The LEL negative drift may occur when the system is first installed and not yet aligned.

  • Page 41: Troubleshooting

    Fault Codes The Ultima OPIR-5 Detector will indicate a fault code number on the three-digit display as an aid to troubleshooting. The following list identifies the fault codes, gives a description of the fault, and indicates the corrective action that should be taken.

  • Page 42: F3 Beam Block

    Ultima OPIR-5 Detector 5.1.4 F3 Beam Block This fault indicates that the infrared source from the Source is too dim. It activates its relay after the user defined beam block timeout period is exceeded. ACTION – The system optical path should be checked for blockage or windows cleaned. If this continues, the unit should be returned for repair.

  • Page 43: F10 Reset Short

    Ultima OPIR-5 Detector 5.1.11 F10 Reset Short This fault indicates that the reset external connection is shorted to ground for more than 30 seconds. ACTION – Remove the reset short wire from ground. 5.1.12 F11 Unit Overheating This fault indicates the Source and/or Receiver unit is over temperature. The Ultima OPIR- 5 Detector continues to detect gas but its accuracy is degraded and the long term reliability is compromised.

  • Page 44: Tf7 Source Heater

    Ultima OPIR-5 Detector 5.1.17 tF7 Source Heater This fault indicates that the heater in the Source has malfunctioned. ACTION – The unit must be returned for repair. NOTE: During the F1, F5, F6, F10, F11, F15, tf7, and F0 for negative drift faults, the unit will attempt to output an alarm if gas is present.

  • Page 45: Receiver Aj Number Went To 0 With No "A" On The Display

    Stack a second magnet onto the first. 5.2.7 Receiver displays information other than described Refer to the Ultima OPIR-5 Detector Receiver User Menu to apply the magnet and resume alignment 5.2.8 Source or Receiver will not move Verify that fine adjust screw tops are flush with the assembly surface.

  • Page 46: Customer Support

    Ultima OPIR-5 Detector 6.0 Customer Support Address Phone/Email UNITED STATES Mine Safety Appliances Co. Toll Free: 1-800-MSA-INST 26776 Simpatica Circle Email: customer.service@MSAsafety.com Lake Forest, CA 92630 Table 4: MSA Location...

  • Page 47: Appendix

    7.0 Appendix Warranty MSA warrants the Ultima OPIR-5 Detector to be free from defects in workmanship or material under normal use and service within two years from the date of shipment. MSA will repair or replace without charge any such equipment found to be defective during the warranty period.

  • Page 48: Specifications

    Ultima OPIR-5 Detector Specifications 7.2.1 System Specifications Infrared Sensor Type: Methane or Propane Gas Detected: Dual Measuring Range: Methane Light Hydrocarbon Unit: 0 to 5,000 ppm•m and 0 to 5 LEL•m Propane Heavy Hydrocarbon Unit: 0 to 2,000 ppm•m and 0 to 1 LEL•m ≤...

  • Page 49: Electrical Specification

    Ultima OPIR-5 Detector 7.2.2 Electrical Specification 20 to 36 VDC, 24 VDC nominal Input Voltage: Source: 0.64 A maximum at 20 VDC input voltage Input Current: Receiver: 0.50 A maximum at 20 VDC input voltage; less 0.04 A with relays disabled...

  • Page 50: Environmental Specification

    Ultima OPIR-5 Detector 7.2.4 Environmental Specification -55°C to +65°C @ 10% to 95% RH non-condensing, Operating Range: 86-108 kPa non-compensated -65°C to +75°C @ 10% to 95% RH non-condensing, Storage Range: 86-108 kPa non-compensated Type 4X, IP66/67 Enclosure Protection Rating: 7.2.5 Approvals...

  • Page 51: Spare Parts And Accessories

    Ultima OPIR-5 Detector Sample Calculations for Analog Output Cable Maximum load is 700 ohms. If an external device has an input impedance of 600 ohms, the cable resistance must not exceed 100 ohms, where maximum load = device load + cable resistance.

  • Page 52: Engineering Documentation

    Ultima OPIR-5 Detector Engineering Documentation Figure 13: Outline Drawing...

  • Page 53: Split-Range Analog Output Option

    4 to 12 mA represent 0 – 5,000 ppm●m and values from 12 to 20 mA represent 0 – 5.0 LEL●m. For the heavy hydrocarbon version of the Ultima OPIR-5 Detector the ranges are 4 to 12 mA represent 0 – 2,000 ppm●m and values from 12 to 20 mA represent 0 – 1 LEL●m.
  • Page 54 Ultima OPIR-5 Detector Technical Index 30878-2, 17 Misalignment, 33 329083, 17, 36 Modes, 33 329084, 17, 36 NEC 500-3d or Canadian Electrical Code Handbook, 7, 11 329084-1, 13 Operating Range, 35 4-20 mA signal, 7 Output Options, 21 Accuracy, 33...
  • Page 55 MINE SAFETY APPLIANCES COMPANY CRANBERRY TOWNSHIP, PENNSYLVANIA, USA 16066 1-800-MSA-INST www.MSAsafety.com...

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