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Troubleshooting
Related Manuals for OSI OFS 2000CW
Summary of Contents for OSI OFS 2000CW
- Page 1 OFS 2000CW User’s Guide Optical Scientific Inc User's Guide OFS 2000CW Optical Flow Sensor 03/28/13 OPTICAL SCIENTIFIC INC 2 Metropolitan Ct, Suite 6 Tel: 301-963-3630 Gaithersburg, MD 20878 USA Fax: 301-948-4674 www.opticalscientific.com P/N 1910-905...
- Page 2 Added explanation for second current loop full scale Updated OFS 2000C User’s Guide to create -CW model User’s Guide 03/28/2013 OFS-2000 Certifications UL 3101-1:1993 CSA C22.2 No. 1010.1:92 IEC 61010:1999 OSi is an ISO-9001 Registered Company P/N 1910-905 Rev. 03/28/13...
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Page 3: Table Of Contents
3.7.1 Transmitter Unit ..........................28 3.7.2 Control Box ............................28 3.8 User Interface Connections ........................29 3.9 OFS 200CW Interconnecting Cables ....................30 3.10 AGC Cable Connections for OFS 2000CW Models ................31 3.11 OFS Receiver Cable ..........................31 3.11.1 Temperature Probe Interconnect ....................32 3.11.2 Activator Heater Interconnect.......................32 3.12 4-20 mA Current Loop Connections ....................33... - Page 4 OFS 2000CW User’s Guide Optical Scientific Inc 5.1.1 "A" Poll Response Bytes ........................42 5.2 "C" Poll (Long Data String) Format .......................43 5.2.1 “C” Poll Response Bytes ........................43 5.2.2 Description of Status Indicator Codes (Bytes 29-32) ...............44 6 Transmitter and Receiver Setup ........................45 6.1 Transmitter Setup ..........................45...
- Page 5 OFS 2000CW User’s Guide Optical Scientific Inc Table of Figures Figure 1.1 OFS 2000CW Basic Components ....................1 Figure 1.2 OFS 2000CW System Components ....................4 Figure 1.3 OFS 2000CW Transmitter ......................5 Figure 1.4 OFS 2000CW Receiver ........................6 Figure 1.5 OFS 2000CW Control Box ......................
- Page 6 Figure 4.12 Clearing Set Points ........................41 Figure 4.13 Duct Area............................41 Figure 4.14 Calibration Percentage N/A ......................41 Figure 6.1 OFS 2000CW TX Module ......................45 Figure 6.2 OFS 2000CW RX Window ......................45 Figure 6.3 Centering Light Beam ........................45 Figure 6.4 TX Rear View..........................45 Figure 6.5 Receiver "A"...
- Page 7 OFS 2000CW User’s Guide Optical Scientific Inc Caveats Only trained personnel are allowed to service this equipment. The OFS shall only be used in a manner specified by the manufacturer. This equipment contains hazardous voltages. Disconnect AC power before servicing.
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Page 8: Ofs -2000Cw Overview
Receiver Control Unit Figure 1.1 OFS 2000CW Basic Components The LED in the transmitter emits a light beam which illuminates twin photodetectors in the receiver. The received signal is amplified and sent to the Digital Signal Processor (DSP) in the Control Unit. The results are shown on the front panel display and relayed to the customer either through a 4-20 mA current loop or through an RS-232 interface. - Page 9 OFS 2000CW User’s Guide Optical Scientific Inc P/N 1910-905 Rev. 03/28/13...
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Page 10: Ofs -2000Cw Specifications
OFS 2000CW User’s Guide Optical Scientific Inc 1.2 OFS -2000CW Specifications Flow Performance Technique Optical scintillation Velocity Range 1.0 to 40 m/s velocity Path Distance 2 to 10+ meters (6 to 30+ feet) Accuracy 2% of reading Resolution 0.1 m/s... -
Page 11: Description Of Units
The Temperature Probe is used to monitor flow temperature. The Activator Heater is used to excite scintillation where air flow is < 150°F [65.6°C] Figure 1.2 OFS 2000CW System Components P/N 1910-905 Rev. 03/28/13... -
Page 12: Ofs 2000Cw Transmitter
Optical Scientific Inc 1.3.1 OFS 2000CW Transmitter The OFS 2000CW TX Unit, P/N 1910-100-1, consists of two major parts, the housing and the flange adapter. Figure 1.3 illustrates the major components of the OFS 2000CW TX Unit. The OFS TX and RX units (with integral spool piece) are designed to mate to an ANSI 150 # 4” flange as is commonly used in commercial applications. -
Page 13: Ofs 2000Cw Receiver (Rx) Unit
OFS 2000CW User’s Guide Optical Scientific Inc 1.4 OFS 2000CW Receiver (RX) Unit The RX Unit, P/N 1910-200 is equipped at the factory with an interconnecting cable for the AGC option. The Receiver consists of two major parts, the housing and the flange adapter (spool piece). Figure 1.4 illustrates the major components of the RX unit. -
Page 14: Control Box
U6 Pressure Sensor connects to filter fitting “Pressure Port” at enclosure bottom TB3 4-20mA Current Loop Outputs [See Sections 3.12 and Section 4.2.4] TB2 Fault Relay, Cal Relay & External Cal Check [See Section 3.13] Figure 1.5 OFS 2000CW Control Box P/N 1910-905 Rev. 03/28/13... -
Page 15: Figure 1.6 Ofs Control Box
OFS 2000CW User’s Guide Optical Scientific Inc TB1 Receiver Power and Signal I/O Digital Signal Processor (DSP) This board is a state-of-the-art digital processor used to convert the optical data from the RX Unit into flow measurements. This data is transmitted to the microcontroller to be integrated into the information data stream. -
Page 16: Figure 1.8 Pressure Sensor
OFS 2000CW User’s Guide Optical Scientific Inc The Pressure Sensor is located on the Control/Interface board. It is a state-of-the-art, monolithic, signal conditioned, silicon piezo-resistive pressure sensor. It connects to a filter fitting at the bottom of the control enclosure. See Figure 1.8. -
Page 17: Temperature Probe
It screws into a 1/2” NPT port and is provided with a cable which plugs into the J3 connector at the bottom of the Control Box. The operational range for OFS 2000CW is -40° to +932°F [- 40°... -
Page 18: Pre - Installation
The OFS will measure at any distance from 0.15 to 10 meters. Other distances are possible. Again consult OSI if you have questions regarding proper placement. Note: In cases like these, it is advisable to mount the units so that the light beam is aligned along the axis of the upstream bend. -
Page 19: Ofs 2000Cw Sensor Placement
OFS 2000CW User’s Guide Optical Scientific Inc 2.2 OFS 2000CW Sensor Placement In addition to the general placement considerations described in the previous section, proper allowance must be made for the location of the Temperature Probe [1910-852] and Activator Heater [1910-850]. -
Page 20: Flange Alignment Guidelines
The first step to getting the most out of your sensor is making sure the mounting flanges are aligned properly. The OFS 2000CW is designed to mount to common ANSI 150# 4“ pipe flanges. These flanges must be installed:... -
Page 21: Flange Mounting Examples
OFS 2000CW User’s Guide Optical Scientific Inc 2.4 Flange Mounting Examples Proper Improper Flange Alignment Flange Alignment OFS Transmitter and One (or both) flanges Receiver are aligned on installed crookedly, the the same axis. The Transmitter and Receiver flanges and openings will... -
Page 22: Flange Pipe Extension
RATA measurement area. The OFS 2000CW has a wide range of applications, and each application has it’s own individual conditions. Proper flange installation and alignment is basic to them all. The guidelines shown here in brief should provide insight to most common considerations in planning or upgrading your installation. -
Page 23: Flange Pipe Mounting
Section 3.4 “Purge Air”. Figure 2.6 Flange Installation - Correct OFS 2000CW is designed to mount to the 4 – inch ANSI 150# pipe flanges commonly used in industry. The standard dimensions are shown at right in Figure 2.7. -
Page 24: Installation
OFS 2000CW User’s Guide Optical Scientific Inc 3 Installation General installation is described here. 3.1 Required at Transmitter or Receiver Location 4-inch ANSI 150# pipe flange (9 inch diameter) Instrument - grade air at 2 CFM per head (See notes in Sections 3.4 “Purge Air” and 3.6 “Z-Purge Air”) -
Page 25: Mechanical
OFS 2000CW User’s Guide Optical Scientific Inc 3.3 Mechanical 3.3.1 TX/RX Units Attach the OFS TX & RX Units to the user-supplied flanges using the hardware as shown in Figure 3.3. Mounting hardware for installation of the units is included. The top view with dimensions in inches for the TX/RX head with Flange Adapter is shown in Figure 3.4. -
Page 26: Figure 3.4 Ofs Tx/Rx Overall Dimensions
OFS 2000CW User’s Guide Optical Scientific Inc Figure 3.4 OFS TX/RX Overall Dimensions Units = inches. P/N 1910-905 Rev. 03/28/13... -
Page 27: Control Units
OFS 2000CW User’s Guide Optical Scientific Inc 3.3.2 Control Units 3.3.2.1 Control Box Figure 3.5 Control Box Mounting Dimensions Note: Depth = 6-3/8 inches. The Control Box may be mounted to a wall or other surface with user-supplied hardware. It should be located within 15 feet of the RX Unit if the standard P/N 1910-217 cable was ordered. -
Page 28: Purge Air
OFS 2000CW User’s Guide Optical Scientific Inc 3.4 Purge Air The OFS 2000CW, being an optical measuring device, needs to “see” clearly. The function of purge air is to keep the interior atmosphere of the mounting nozzle clear, the light path unobstructed, and provide an air barrier to slow the rate of deposition on the window. -
Page 29: Figure 3.10 Purge Air At 90° To Vertical Flow
It is recommended that a regulator and rotameter be installed near the OFS heads to control the airflow. OSI can supply a rotameter (1910-453) specifically tailored for OFS use. -
Page 30: Ofs In Hazardous Or High Temperature Applications
In these cases installation of a gate valve and sight glass is also recommended. OSI offers these two components as options which may be ordered with the systems. They are 1910-420 Cast Iron Gate Valves (2 required per system) -
Page 31: Pressurization Air (Z-Purge Air)
When applied together they may be supplied from the same primary source, but their control and application must be independent. Customers may elect to configure their pressurization systems to meet their own standards and practices. OSI offers an equipment package which meets established North American requirements and has been found to work satisfactorily. This package and recommended configuration is, “designed to protect electrical... -
Page 32: Figure 3.15 Typical Z-Purge Control Unit
OFS 2000CW User’s Guide Optical Scientific Inc Type Z applications reduce the hazardous location rating inside the enclosure from Division 2/ Zone 2 to non-hazardous. This allows general purpose equipment to operate in Division 2/ Zone 2 areas. This unit is designed to... -
Page 33: Unit Tubing Instructions
OFS 2000CW User’s Guide Optical Scientific Inc Z-Purge connection to the Control box is straightforward as shown. The Purge Vent is a gravity-operated enclosure pressure relieving device designed to relieve excess pressure inside a protected enclosure while preventing any sparks or burning material from escaping into a classified location. -
Page 34: Pressurization Unit Operation
OFS 2000CW User’s Guide Optical Scientific Inc 5. Slowly turn Enclosure Pressure Control Regulator CW until a “Safe” 0.5” w.c. reading is shown on the Enclosure Pressure Gauge. Note: If unable to achieve a “ Safe” enclosure pressure, carefully check all enclosure connections and doors for leakage. Seal as needed. -
Page 35: Ac Power Connections
OFS 2000CW User’s Guide Optical Scientific Inc 3.7 AC Power Connections Power Requirements: single phase, 100-240 VAC, 50/60 Hz @ 1 A. 3.7.1 Transmitter Unit AC power connections to the TX Unit are made to TB1 of the TX circuit board located on the left inside of the TX housing. -
Page 36: User Interface Connections
OFS 2000CW User’s Guide Optical Scientific Inc 3.8 User Interface Connections The OFS has two communication modes: Analog Digital 4-20mA Current Loop Outputs RS-232 Serial Data Output Fault Relay & Cal Relay Control Interface External Cal Switch Figure 3.20 User Analog Interface Connections... -
Page 37: Ofs 200Cw Interconnecting Cables
OFS 2000CW User’s Guide Optical Scientific Inc 3.9 OFS 200CW Interconnecting Cables The OFS 200CW and CW cables are connected as shown in Figures 3.22 and 3.23. The Receiver Cable 1910-217 supplies DC power to the receiver electronics, and signal data to the Digital Signal Processor (DSP) in the control unit. -
Page 38: Agc Cable Connections For Ofs 2000Cw Models
OFS 2000CW User’s Guide Optical Scientific Inc 3.10 AGC Cable Connections for OFS 2000CW Models Figure 3.24 TX AGC Cable Connection Figure 3.25 RX AGC Cable Connection 3.11 OFS Receiver Cable OFS Receiver Cable (1910-217) is supplied in standard length of 15 feet. Customers may order extra length up to 400 feet using the following number scheme ex. -
Page 39: Temperature Probe Interconnect
OFS 2000CW User’s Guide Optical Scientific Inc 3.11.1 Temperature Probe Interconnect The Temperature Probe is equipped with a 25’ cable. This cable plugs into the J3 connector at the bottom of the Control Box. The signal from the RTD in the Temperature Probe is routed to the Sensor Interface Board in the Control Box where it is processed and sent to the DSP for integration into the system data. -
Page 40: Ma Current Loop Connections
OFS 2000CW User’s Guide Optical Scientific Inc 3.12 4-20 mA Current Loop Connections The terminal block TB3 of the interface board connects to isolated 4-20 mA circuitry, diagnostic relay, calibration relay and calibration check request interface. The pin designation is as follows:... -
Page 41: Tb2 Fault / Cal Relays & External Calibration
OFS 2000CW User’s Guide Optical Scientific Inc 3.13 TB2 Fault / Cal Relays & External Calibration 3.13.1 Fault Relay Pins COM 1 and NC 1 are connected to a dry contact relay The contacts close when the system is powered up, and remain so during normal operation. -
Page 42: Computer Connection
An advantage of OSI’s SQC software is that it creates a time stamp for every line of data so that events can be easily compared with process data. -
Page 43: Hyperterminal Setup
OFS 2000CW User’s Guide Optical Scientific Inc 3.14.1 HyperTerminal Setup 1. The Connect to Window will open offering dial-up, COM port or TCP/IP options. Choose the COM port corresponding to the cable connection and click “OK”. 2. The COM Port Properties window will open showing Port Setting options. Choose:... -
Page 44: Ofs System Configuration Setup
OFS 2000CW User’s Guide Optical Scientific Inc 4 OFS System Configuration Setup 4.1 Checking Communications At this point you should have serial communications established between the computer and the OFS as described in Section 3.14.1. ”HyperTerminal Setup”. Check the status bar at the bottom of the HyperTerminal window. -
Page 45: Time Constant
OFS 2000CW User’s Guide Optical Scientific Inc 4.2.2 Time Constant Enter “S” to display the Setup parameters list, and enter “1” to choose the averaging time setting While setting up the meter or doing trouble shooting, the averaging time should be set to a short time duration (10 seconds or 3 seconds) for rapid response to any parameter changes. -
Page 46: Correction Factor
OFS 2000CW User’s Guide Optical Scientific Inc Current Loop (continued) Current Loop 1 - Velocity sets the velocity measurement range. Default velocity range is 0 to 40 m/s (meters per second). The user can opt for a lesser range by entering “1” and following the prompt. -
Page 47: Multiple Point Correction Factor
OFS 2000CW User’s Guide Optical Scientific Inc 4.2.6 Multiple Point Correction Factor (Curve Fitting) In the ordinary run of operation, flow will remain fairly constant, and a simple setup will meet your needs. However, in some cases the output flow from the process will vary sufficiently to require a more dynamic response to more effectively monitor a process. -
Page 48: Duct Area Data
OFS 2000CW User’s Guide Optical Scientific Inc Multiple Point Correction Factor (continued) Should it be necessary to return the OFS to basic flow reporting, all correction factor entries may be cleared by simply entering a zero (“0”) as prompted. It is also recommended to clear correction factor settings when updating or entering new settings. -
Page 49: Poll Commands & Data Output
OFS 2000CW User’s Guide Optical Scientific Inc 5 Poll Commands & Data Output When being operated in RS-232 mode the OFS outputs conventional ASCII data strings in response to single character poll commands sent by the user’s Data Acquisition System (DAS) or computer. Besides use in ordinary operation, the poll commands and resulting data outputs can be useful in determining system status, diagnostics, and troubleshooting. -
Page 50: C" Poll (Long Data String) Format
OFS 2000CW User’s Guide Optical Scientific Inc 5.2 "C" Poll (Long Data String) Format Format: Byte: Format: Byte: Format: Byte: Format: Byte: 5.2.1 “C” Poll Response Bytes Field Byte Description Details Symbol Fixed Field – Velocity Wind Indicator Comma delimiter... -
Page 51: Description Of Status Indicator Codes (Bytes 29-32)
OFS 2000CW User’s Guide Optical Scientific Inc Pressure Fixed Field - Pressure Comma delimiter 63-66 pppp Pressure in hPa (1013 hPa = 1 Atm) Comma delimiter Fixed Field – Heater Current Heater Rod Current Comma delimiter 70-73 kkkkk Heater Current in Amp * If some of the Aux inputs are disabled, the corresponding data fields are dashed out so that it does not cause fault condition. -
Page 52: Transmitter And Receiver Setup
The Receiver module is equipped with reflectors to aid in sighting. Note: Under certain operating conditions, it may be difficult to see the reflection from the receiver module. Figure 6.1 OFS 2000CW TX Module Figure 6.2 OFS 2000CW RX Window ! CAUTION ! AC Line voltage will be present in the transmitter enclosure. -
Page 53: Receiver Setup
OFS 2000CW User’s Guide Optical Scientific Inc 6.2 Receiver Setup Mount the receiver head in place. Connect all cables Locking screw and any air lines. See that all seals are tight. Reflective Arrow The receiver module can be rotated to allow for... -
Page 54: Optical Alignment
OFS 2000CW User’s Guide Optical Scientific Inc 7 Optical Alignment How well the details of the receiver board and detectors can be seen during aiming depends on several factors such as distance, the amount of mist or particulate in the gas stream, the amount of ambient light. These can combine to make it difficult to see where the “spot”... -
Page 55: Figure 7.2 Transmitter Module
OFS 2000CW User’s Guide Optical Scientific Inc 7 Optical Alignment (Continued) appropriate terminal strip locations (C1, C2 and Ground) on TB J2 on the Receiver board. DO NOT lift the wire that is already in those locations but slip your wire in beside it and tighten the screw back down. The scale will be different than on the controller display and will be approximately 0-2.5 volts. - Page 56 OFS 2000CW User’s Guide Optical Scientific Inc P/N 1910-905 Rev. 03/28/13...
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Page 57: Avoiding Receiver Saturation
OFS 2000CW User’s Guide Optical Scientific Inc 7. Optical Alignment (Continued) The A & B voltages do not have to be identical for the OFS to operate correctly. Generally, A & B voltages should be within a maximum of 30% of each other. Velocity measurement is not dependent on the amplitude of the A &... -
Page 58: Correlation
However, this condition can be overcome. The OFS 2000CW is designed to operate properly in a wide range of conditions. Following the instructions in this User’s Guide, and other OSI application notes, should result in a non-problematic, well-functioning system. -
Page 59: Initial Check And Start-Up
OFS 2000CW User’s Guide Optical Scientific Inc 9 Initial Check and Start-Up 9.1 Initial Check It is advisable to read through this manual before initial start of the system but if you are already familiar with the analyzer and just need a quick startup guide, follow these steps. . Although this procedure may be done at any time, for best results it should be performed while the user’s process is running. -
Page 60: Figure 9.3 Control Enclosure Display
Figure 9.4 Control & DSP Indicator LED's If there are questions regarding the system, collect system data as shown in Section 5.2 and contact OSI Technical Support as shown in Section 13 P/N 1910-905... -
Page 61: Maintenance
OFS 2000CW User’s Guide Optical Scientific Inc 10 Maintenance 10.1 Safety This equipment does not contain any operator replaceable parts. Only trained personnel are allowed to service this equipment. This equipment contains hazardous voltages. Disconnect AC power before servicing. Read the entire User's Guide before proceeding with installation or maintenance! 10.2 Preventive Maintenance... -
Page 62: Window Cleaning Procedure
OFS 2000CW User’s Guide Optical Scientific Inc 10.2.1 Window Cleaning Procedure Loosen the top TX/RX Head mounting flange bolt and take off the remaining three. Carefully rotate the TX/RX Head around the remaining top bolt so that the window is exposed. -
Page 63: Troubleshooting
If (after consulting with OSI Tech Support) it is determined that there is a problem with a circuit board. You may order a replacement from OSI. Operating firmware or DSP software are not field replaceable or upgradeable unless done by OSI or OSI-approved personnel. -
Page 64: Control Enclosure Troubleshooting
OFS 2000CW User’s Guide Optical Scientific Inc 11.2 Control Enclosure Troubleshooting There are no user-serviceable parts in the Control enclosure. Information provided herein may be helpful when contacting OSI Technical Support. The Control/Interface Board and DSP (Digital Signal Processing) board have indicator LED’s which... -
Page 65: Receiver "Signal" Led Not Lit
OFS 2000CW User’s Guide Optical Scientific Inc 11.4.2 Receiver "Signal" Led Not Lit Be sure the transmitter is transmitting Be sure the light beam path is unobstructed and the windows are clear. Check alignment as shown previously in this document. -
Page 66: Error Messages
Some (not all) messages are triggered by status indicator code byte 31 found in the “C” poll data output stream. [Section 5.2.2] A brief explanation is provided below. In most cases, the problem can be easily resolved with standard trouble shooting methods. If you require further assistance, contact OSI Technical Support [See Section 13 “Technical Support”] 11.5.1 Fault (1) A and/or B Out of Range... -
Page 67: Spare Parts
OFS 2000CW User’s Guide Optical Scientific Inc 12 Spare Parts 12.1 Recommended Spare Parts For OFS installations where multiple units are installed or where it is “process critical”, We recommend purchase of an entire unit as a spare to keep downtime to a minimum. For installations where a short down- time is acceptable, we recommend these spares, shown below along with the complete table of available spares. -
Page 68: Technical Support
OFS 2000CW User’s Guide Optical Scientific Inc 13 Technical Support OSI Technical Support techsupport@opticalscientific.com Tel: 301 963 3630 xt 216 Fax: 301 948 4670 9AM – 5PM Eastern Time Monday – Friday (except national holidays) Telephone assistance for overseas customers is available by appointment. - Page 69 A hot, rapidly-moving air mass will show a great deal of thermal turbulence (elevated correlation). A minimum threshold flow temperature of 100° F (38° C) will be generally sufficient for good correlation. If low correlation is a constant problem, contact OSI Engineering Dept.
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