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Lighthouse Worldwide Solutions REMOTE 5104V Operating Manual

Airborne particle counter
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Summary of Contents for Lighthouse Worldwide Solutions REMOTE 5104V

  • Page 3 Lighthouse Worldwide Solutions REMOTE 5104V Airborne Particle Counter Operating Manual...
  • Page 4 Copyright © 2006 - 2013 by Lighthouse Worldwide Solutions. All rights reserved. No part of this document may be reproduced by any means except as permitted in writing by Lighthouse Worldwide Solutions. The information contained herein constitutes valuable trade secrets of Lighthouse Worldwide Solutions.
  • Page 5 EU DECLARATION OF CONFORMITY Manufacturer’s Name: Lighthouse Worldwide Solutions, Inc. Manufacturer’s Address: Lighthouse Worldwide Solutions, Inc. 1221 Disk Drive Medford, OR 97501 Declares that the product: Product Name: Remote Airborne Particle Counter Model Number(s): REMOTE 2014V, 3014V, 5014V, 5104V Conforms to the following Product Specifications:...
  • Page 6 EN61326 Electrical Equipment for Measurement, Control and Laboratory Use EMC Requirements Part 1: General Requirements Includes Amendment A1:1998;IEC 61326:1997 + A1:1998 21CFR-Part 211 Guidance for industry Sterile Drug Products, Produced by Aseptic Processing Current Good Manufacturing Practice: Remote Particle Counting Probe UL 61010A-1 –...

  • Page 7: Table Of Contents

    R5104V and Daisy Chaining ..................1-4 Chapter 2 Introduction Overview ........................2-1 Description ........................2-1 Accessories ........................2-2 REMOTE 5104V Specifications ................... 2-3 Chapter 3 Getting Started Initial Inspection ......................3-1 Shipping Instructions ..................... 3-1 Cable Build ........................3-2 Requirements ..................... 3-2 Site Preparation ....................
  • Page 8 Lighthouse REMOTE 5104V Operating Manual Connections ..................... 3-11 .Communication Ports ..................3-12 Cabling Sensor ....................3-12 DIP Switches ....................3-15 Instrument Mounting ..................3-15 Power ....................... 3-16 Vacuum Inlet ....................3-16 Chapter 4 Communications DIP Switches ........................4-1 DIP Switch General Definitions ................ 4-2 Communication Modes ................
  • Page 9 Table of Contents Threshold Setup Registers ................A-8 Setting the Alarm Threshold Value ............A-9 Data Registers ....................... A-9 Device Status Word ..................A-11 Data Enable Registers ..................A-11 Data Type Registers ..................A-12 Data Units Registers ..................A-13 Appendix B Maintenance Safety Considerations ....................
  • Page 10 Lighthouse REMOTE 5104V Operating Manual t-iv 248083293-1 Rev 7...
  • Page 11 LASER Warning Label on Unit ... 1-1 Explosion Hazard Label ... 1-2 R5104V Label with Hazard Symbol ... 1-3 REMOTE 5104V Airborne Particle Counter ... R5104V RJ45 Cable Parts ... 3-4 Housing with Cable Inserted ... 3-4 Close-up of Wire Loom ... 3-5 EIA/TIA-568B Color Code Example ...
  • Page 12 Lighthouse REMOTE 5104V Operating Manual LOF-2 248083293-1 Rev 7...
  • Page 13 List of Tables REMOTE 5104V Specifications ... 2-3 DIP Switch settings ... 4-2 DIP Switch Communications Mode ... 4-2 DIP Switch Addressing ... 4-3 RJ-45 Pinouts ... 4-4 EIA RS-485 Communication Standards ... 4-5 MODBUS Action Commands ... 5-2 Real Time Clock Registers ... 5-3 Data Set Registers ...
  • Page 14 Lighthouse REMOTE 5104V Operating Manual LOT-2 248083293-1 Rev 7...

  • Page 15: About This Manual

    Indicates a comment on a command or Helvetica Italics text output. Additional For more information about Lighthouse REMOTE 5104V Airborne Particle Counters, contact Lighthouse Worldwide Solutions: Help Service and Support Tel: 800-945-5905 (USA Toll Free) Tel: 541-770-5905 (Outside of USA) techsupport@golighthouse.com...
  • Page 16 Lighthouse REMOTE 5104V Operating Manual 248083293-1 Rev 7...

  • Page 17: Chapter 1 Safety

    Safety Safety Warnings and cautions are used throughout this manual. It is the Considerations responisbility of the user to familiarize themselves with the meaning of a warning before operating the particle sensor. All warnings will appear in the left margin of the page next to the subject or step to which it applies.
  • Page 18 Lighthouse REMOTE 5104V Operating Manual The particle counter has been evaluated and tested in accordance with ISA-82.02.01 2 Ed., July 2004, "Safety Requirements For Electrical Equipment for Measurement, Control, and Laboratory Use" and ANSI/ ISA-12.12.01-2000, "Nonincendive Electrical Equipment for Use in Class I and II, Division 2 and Class III, Divisions 1 and 2 Hazardous (Classified) Locations.
  • Page 19 Safety WARNING: EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS. AVERTISSEMENT - RISQUE D’EXPLOSION - AVANT DE DÉCONNECTER L’EQUIPMENT, COUPER LE COURANT OU S’ASSURER QUE L’EMPLACEMENT EST DÉSIGNÉ NON DANGEREUX.

  • Page 20: Electrostatic Safety Information

    R5104V and WARNING: The REMOTE 5104V is not designed for use in a daisy chain configuration. It is designed to communicate through Daisy a single RJ45 connector and must be used in a star (connected to Chaining a hub) or a single-point (i.e., connected to a single PC)

  • Page 21: Chapter 2 Introduction

    Introduction Overview This operating manual introduces the Lighthouse REMOTE 5104V family of Airborne Particle Counters. Also included in this manual are instructions for inspecting, using, and maintaining the instrument. Description The 5104V instrument has up to four particle-size channels starting at 0.5 microns with a flow of 1.0 CFM.

  • Page 22: Accessories

    Class 10) and also in more traditional cleanzones rated as Class 100 or higher. Refer to Specifications in this manual for additional instrument information. The REMOTE 5104V line of Airborne Particle counters was designed for continuous operation. Using an external vacuum source, the instrument provides versatile mounting options and can be installed where minimal space is available.

  • Page 23: Remote 5104V Specifications

    Storage Temp/RH 14° F to 122° F (-10° C to 50° C) / Up to 98% non-condensing Table 2-1 REMOTE 5104V Specifications The manufacturer recommends that the Lighthouse instrument be calibrated annually by a Certified Lighthouse Service Provider to ensure that it continues to perform within specification.
  • Page 24 Lighthouse REMOTE 5104V Operating Manual 248083293-1 Rev 7...

  • Page 25: Chapter 3 Getting Started

    Getting Started Getting Started Initial The instrument is thoroughly inspected and tested at the factory and is Inspection ready for use upon receipt. When received, inspect the shipping carton for damage. If the carton is damaged, notify the carrier and save the carton for carrier inspection. Inspect the unit for broken parts, scratches, dents, or other damage.

  • Page 26: Cable Build

    Lighthouse REMOTE 5104V Operating Manual Cable Build The REMOTE 5104V is not designed for use in a daisy chain configuration. It is designed to communicate through a single RJ45 connector and must be used in a star (connected to a hub) or a single-point (i.e., connected to a single PC) configuration...
  • Page 27 Getting Started 1. Check with local regulatory agencies to determine installation restrictions and cable requirements for the application before starting cable runs. 2. Make the necessary cable "runs" and leave about two to three feet at each end as a "service loop". When pulling CAT5e cable, do NOT allow it to kink or the cable may break internally and cause failures.

  • Page 28: Procedure

    Lighthouse REMOTE 5104V Operating Manual Procedure 1. Strip 1-1/2-inch to two-inches of insulation from the end of the cable, taking extreme care to not nick or cut the individual wires. Do NOT strip the individual wires. 2. Remove the contents of the Industrial RJ45 connector from the package - do NOT dispose of or lose any pieces.
  • Page 29 Getting Started 6. Separate the pairs of wires down to the cable’s insulation. There will be an orange, a green, a blue and a brown pair of wires. Each pair will have a solid color wire and one striped wire of the pair color.
  • Page 30 Lighthouse REMOTE 5104V Operating Manual Note: 9. Continue to push the cable into the loom and trim the ends of the The "pairing" of wires in the loom changes wires in a straight line to one-eighth-inch as illustrated in the center at positions 4 through 6.
  • Page 31 Getting Started 13. Pull on the cable to bring the RJ-45 into the connector housing. Make sure to squeeze the latch tab to allow it to enter the slot in the housing See Figure 3-8. Figure 3-8 Close-up of RJ-45 Latch 14.
  • Page 32 Lighthouse REMOTE 5104V Operating Manual 16. Install the sealing ring onto the front of the connector housing. This seal is held in place when the connector is locked onto the instrument. See Figure 3-11. Figure 3-11 Install Connector Seal 17. Slide the large lock ring down the cable and over the cable housing body.
  • Page 33 Getting Started 19. Use the template shown in Figure 3-13 to locate and install the R5104V securely on a flat vertical surface in the area to be sampled.  > PP@ 02817,1* +2/(   Figure 3-13 Mounting Template 20. Make sure the hub power is OFF or the hub end of the cable is disconnected from the hub before connecting the cable to the instrument.

  • Page 34: Operation

    Lighthouse REMOTE 5104V Operating Manual Operation Understanding the LEDs The front-panel LEDs have specific meanings when illuminated. Figure 3-14 shows location of the LEDs and gives a brief description of their meaning Figure 3-14 Front Panel LEDs • The green POWER LED turns on when the instrument is powered •...

  • Page 35: Connections

    Getting Started Connections The top of the instrument has a connection for an isokinetic inlet probe. See Figure 3-15. Inlet Figure 3-15 Instrument Top Connections The sensor can be used with a direct-mount 1.0 CFM isokinetic probe or the probe can be attached via tubing to the inlet barb. Figure 3-16 illustrates the connections found on the bottom side of the R5104V, which include the vacuum source fitting, Data connector and the DIP switch cover plate.

  • Page 36: Communication Ports

    Lighthouse REMOTE 5104V Operating Manual Vacuum supplied to the fitting must be 18" Hg or greater for the R5104V to operate properly and the RS-485 IN port (Data connector) must be used to connect the instrument to a ’star’ or single-point communication.
  • Page 37 Figure 3-17 Readying Cable for Attachment WARNING: REMOTE 5104V is not designed for use in a daisy chain configuration. It is designed to communicate through a...
  • Page 38 Lighthouse REMOTE 5104V Operating Manual 2. Figure 3-19 shows the twist motion required to lock cable into place - make sure the lock groove and lock sleeve mate. Lock groove Figure 3-19 Cable Receptacle Lock Groove 3. Figure 3-20 illustrates the cable as fully attached to sensor. The free end of the cable may now be connected to the RS-485 hub, power applied to the hub and the sensor powered up.

  • Page 39: Dip Switches

    Getting Started DIP Switches The DIP switches are used for addressing the instrument for RS-485 daisy chain configurations and setting the communications mode. See “DIP Switch Communications Mode” on page 4-2 for details. Positions 1-6 set the address of the instrument. Position 7 and 8 set the communications mode.

  • Page 40: Power

    1.0 cfm through the sensor. The flow is controlled by an internal critical orifice. If not enough vacuum is present to provide 1.0 CFM, the FLOW LED will blink. In this case, please contact Lighthouse Worldwide Solutions Technical Support at techsupport@golighthouse.com. 3-16...

  • Page 41: Chapter 4 Communications

    Communications This chapter contains information regarding the communications hardware and how to configure the hardware to allow interfacing with the REMOTE instrument. DIP Switches The DIP switches are behind a panel to the right of the RS-485 port connector. See Figure 4-1. Figure 4-1 DIP Switch Cover Remove the two Phillips head screws to expose the DIP switches.

  • Page 42: Dip Switch General Definitions

    Communication Used in conjunction with DIP Mode switch 7 to set MODBUS mode Communication Modes The communication mode used for the REMOTE 5104V is MODBUS protocol mode. See Table 4-2. Table 4-2 DIP Switch Communications Mode COMMUNICATIONS MODE SW 7...

  • Page 43: Dip Switch Addressing

    Communications DIP Switch Addressing Note: Table 4-3 details the addresses set by the binary DIP switches 1-6. Because Address 0 is reserved for Table 4-3 DIP Switch Addressing broadcasting in MODBUS RS-485 communications, Address 1 is set when all DIP SWITCHES DIP SWITCHES ADDRESS ADDRESS...

  • Page 44: Communicating With The Instrument

    Lighthouse REMOTE 5104V Operating Manual Table 4-3 DIP Switch Addressing DIP SWITCHES DIP SWITCHES ADDRESS ADDRESS 1 2 3 4 5 6 1 2 3 4 5 6 0 0 0 1 1 0 0 0 0 1 1 1...
  • Page 45 Communications 1. Remove power from the hub. 2. Connect one end of the RJ-45 cable to the RS-485 converter: pin 4 to ChB+ and pin 5 on ChA-. 3. Connect the other end of the RJ-45 cable to a port on the hub. 4.
  • Page 46 Lighthouse REMOTE 5104V Operating Manual 248083293-1 Rev 7...

  • Page 47: Chapter 5 Programming With Modbus Protocol

    Programming with MODBUS Protocol The REMOTE 5104V family of instruments can be programmed using the MODBUS Protocol. The full protocol is detailed in “R5104V MODBUS Register Map v1.44” on page A-1. This chapter contains the information needed to program the basic configuration for the instrument using the MODBUS protocol.

  • Page 48: Running The Instrument Using Modbus

    Lighthouse REMOTE 5104V Operating Manual Running the The applicable action commands are displayed in Table 5-1. Instrument Table 5-1 MODBUS Action Commands Using MODBUS Value Action Saves all writable 4xxxx register values to the EEPROM. Clears the Data Buffer. Record count is set to zero.

  • Page 49: Manual Counting Mode

    Programming with MODBUS Protocol MANUAL Counting Mode In Manual counting mode, the computer starts the sample and the instrument continues counting until a stop command is given. At that point, the sample time is listed at whatever the time interval was between the start command and the stop command.

  • Page 50: Changing The Default Instrument Parameters

    Lighthouse REMOTE 5104V Operating Manual Table 5-3 Data Set Registers Register Data Type Description 40036 unsigned integer Data Set [low] Then write the command 13 to the command register 40002. This will write the values in the Data Set registers (40035 and 40036) to the RTC registers (40027 and 40028).

  • Page 51: Using Sensor Setting Registers

    Programming with MODBUS Protocol Using Sensor Setting Registers Certain configuration settings can be sent to the counter through these registers. Sensor Setting Registers 40001 and 40003 through 40023 are protected and should not be changed. Location (Register 40026) For Particle Counters, this value specifies at what location a sample was recorded.

  • Page 52: Alarm Enable Registers

    Lighthouse REMOTE 5104V Operating Manual Alarm and Alarm Enable Registers Threshold The Alarm Enable input registers (43xxx series) shown in Table 5-5 are Registers read/write. All enable data items are 4 bytes long and are stored across 2 registers. Byte and word ordering is big-endian. Thus, data items are formed by placing the high bytes in front of the low bytes.

  • Page 53: Enable Alarming For A Channel

    Programming with MODBUS Protocol Table 5-6 Alarm Enable Registers Register Data Type Description 43015 unsigned int Alarm Enable for Particle Channel 4 [high] 43016 unsigned int Alarm Enable for Particle Channel 4 [low] Enable Alarming for a Channel Alarm and threshold registers are independent of each other. Any one register’s settings will not affect the others and any channel alarms may be enabled or disabled as the user requires.

  • Page 54: Setting The Alarm Threshold Value

    Lighthouse REMOTE 5104V Operating Manual The Data Status flag is set if any of the channels have a threshold exceeded state as true. Note: The Threshold registers (45xxx series) run in parallel with the data The REMOTE comes standard with 2 registers (30xxx series).

  • Page 55: Appendix A R5104V Modbus Register Map V1.44

    R5104V MODBUS Register Map v1.44 COMM Lighthouse particle counters with MODBUS have the following Settings communications settings: Table A-1 MODBUS Communications Settings Baud Rate 19200 Data Bits Stop Bits Parity None Hardware Protocol RS-232-C or RS-485 standard Software Protocol MODBUS ASCII (supports upper/lower case) The MODBUS slave address is set on the particle counter.

  • Page 56: Sensor Settings Registers

    Lighthouse REMOTE 5104V Operating Manual Register Map Sensor Settings Registers Instrument settings are stored in holding registers (the 4xxxx series), which are mostly read/writable. Not all holding registers are writable. Table A-2 describes the content of these registers. Table A-3 Sensor Settings Registers...
  • Page 57 R5104V MODBUS Register Map v1.44 Table A-3 Sensor Settings Registers Register Data Type Description 40020 ASCII string Model Name char[10], char [11] 40021 ASCII string Model Name char[12], char [13] 40022 ASCII string Model Name char[14], char [15] 40023 unsigned integer Flow Rate.

  • Page 58: Device Status

    Lighthouse REMOTE 5104V Operating Manual Table A-3 Sensor Settings Registers Register Data Type Description 40039 unsigned integer Laser Reference Voltage (millivolts) 40041 ASCII string Flow Unit - Defines the Unit that FlowRate value is based on. char[0], char[1]. (NULL-terminated string)
  • Page 59 R5104V MODBUS Register Map v1.44 response. When this register is read, it always returns a zero. Table A-5 Command Register Value Action Saves all writable 4xxxx register values to the EEPROM. Reserved for future use. Clears the Data Buffer. Record count is set to zero. Saves the instrument parameters in the 40xxx registers to the EEPROM.

  • Page 60: Alarm Enable Registers

    Lighthouse REMOTE 5104V Operating Manual Table A-5 Command Register Value Action Set Real Time Clock. Writes "Data Set" values (from Registers 40035 & 40036) to the local Real Time Clock. New time value is saved. Alarm and Alarm Enable Registers Threshold The Alarm Enable input registers (43xxx series) are read/write.

  • Page 61: Enable Alarming For A Channel

    R5104V MODBUS Register Map v1.44 Particle data registers for the Alarm Enable setting start at 43009 for the high word and 43010 for the low word for channel 1. Table A-7 Alarm Enable Registers Register Data Type Description 43009 unsigned int Alarm Enable for Particle Channel 1 [high] (smallest particle size starts here) 43010...

  • Page 62: Threshold Setup Registers

    Lighthouse REMOTE 5104V Operating Manual Threshold Setup Registers Threshold data is stored in the input registers in the 45xxx series which are read/write. All threshold data items are 4 bytes long and are stored across 2 registers. Byte and word ordering is big-endian. Thus, data items are formed by placing the high bytes in front of the low bytes.

  • Page 63: Setting The Alarm Threshold Value

    R5104V MODBUS Register Map v1.44 Setting the Alarm Threshold Value Note: The Alarm Threshold Value is set in the low register of the channels. Thresholds are independent of each so the Each channel has independent threshold value registers. Setting a value set for one channel value for channel 1 as 100 will not affect channel 2 setting of, say, 500.
  • Page 64 Lighthouse REMOTE 5104V Operating Manual Table A-11 Data Registers Register Data Type Description 30004 unsigned integer Sample Time [low] 30005 unsigned integer Location [high] (Place where data was recorded) 30006 unsigned integer Location [low] 30007 unsigned integer Device Status [high]...

  • Page 65: Device Status Word

    R5104V MODBUS Register Map v1.44 Device Status Word Note: The registers used for the Device Status Word are 30007 and 30008. Although MODBUS sends 4 bytes of status information, The bit order of the Device Status Word is 7 to 0 (right to left), where Lighthouse instruments bit 7 is the most significant bit and bit 0 is the least significant bit.

  • Page 66: Data Type Registers

    Lighthouse REMOTE 5104V Operating Manual Data Type Registers Note: The 32xxx register series is used to identify the type of data in the All data records have the same data types 30xxx series. The Data Type registers run in parallel with the Data assigned to them.

  • Page 67: Data Units Registers

    R5104V MODBUS Register Map v1.44 represent raw counts only. Table A-14 Examples of Particle Data Items String Description Particle type of size 0.3 micron Particle type of size 1.0 micron 20.0 Particle type of size 20.0 micron .015 Particle type of size 0.015 micron or 15 nanometer Data Units Registers The 33xxx register series identifies the units used by data items in the 30xxx series.
  • Page 68 Lighthouse REMOTE 5104V Operating Manual Note: Table A-15 shows Units that may be used by the device for recording Be aware that LWS Particle Counters data. Not all Units are used by the device and are reserved for other may use units not on the equipment or for future use.

  • Page 69: Appendix B Maintenance

    Maintenance Safety Warnings and cautions are used throughout this manual. It is the Considerations responsibility of the user to familiarize themselves with the meaning of a warning before operating the particle sensor. All warnings will appear in the left margin of the page next to the subject or step to which it applies.
  • Page 70 Lighthouse REMOTE 5104V Operating Manual WARNING: The use of controls, adjustments, or performance of WARNING procedures other than those specified within this manual may result in exposure to invisible EXPLOSION HAZARD (infrared) radiation that DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS AREA IS KNOWN TO...

  • Page 71: Appendix C Limited Warranty

    BILITY, OR PRODUCT LIABILITY CLAIM AND BUYER AGREES TO WAIVE SUCH CLAIMS. LWS’s SOLE AND EXCLUSIVE LIABILITY AND BUYERS SOLE AND Lighthouse Worldwide Solutions (LWS) warrants that all EXCLUSIVE REMEDY, FOR ANY NONCONFORMITY OR equipment shall be free from defects in material and...
  • Page 72 Lighthouse REMOTE 5104V Operating Manual 248083293-1 Rev 7...
  • Page 73 Index Numerics Data Type Registers A-12 Data Units Registers A-13 Default Instrument Parameters 5104 instrument 2-1 Changing 5-4 Device Status A-4 Device Status Word A-11 Differential Mode of Operation 4-5 Accessories 2-2 Dimensions 2-3 Additional help i-i DIP SWITCH GENERAL DEFINITIONS 4-2 Alarm Enable Registers 5-6, A-6 DIP Switches 3-15, 4-1, 5-1 Alarm Registers...
  • Page 74 Lighthouse REMOTE 5104V Operating Manual Plenum Cable 3-3 Pollution Degree 2-3 Power 3-16 Initial Inspection 3-1 Programming with MODBUS Protocol 5-1 Input Power Requirements 2-3 Real Time Clock laser diode 2-1 Setting 5-3 Laser Source 2-3 Receiver Input Sensitivity 4-5...
  • Page 75 Index Setting the Alarm Threshold Value 5-8, A- To disable alarming 5-7 To enable alarming 5-7 To enable the Alarm 5-6 Understanding the LEDs 3-10 Unshielded Twisted Pair (UTP) 3-3 Vacuum Inlet 3-16 Warning Electrostatic Discharge 1-4 Infrared Radiation 1-2, B-2 Warnings 1-1 Weight 2-3 Zero Count Level 2-3...
  • Page 76 Lighthouse REMOTE 5104V Operating Manual 248083293-1 Rev 7...

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