Dover OPW 8811N Operation Manual
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Dover OPW 8811N Operation Manual

Dover OPW 8811N Operation Manual

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Operation Manual
OPW Engineered Systems
Rack Monitor 88xxE

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Summary of Contents for Dover OPW 8811N

  • Page 1 Operation Manual OPW Engineered Systems Rack Monitor 88xxE...
  • Page 2 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Disclaimer This manual provides important safety and technical information of the OPW Rack monitor 88XX-series. It is important that this manual is read and understood completely by the installing technician prior to installation.
  • Page 3 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change OPW Engineered Systems OPW Fluid Transfer Group Europe BV Visiting address: 9393 Princeton Glendale Road Visiting address: Hamilton, Ohio 45011 Roggestaat 38 PHONE:: 513-932-9114 or 800-547-9393 2151BC Nieuw Vennep FAX: 513-932-9845 or 800-245-8536 PHONE:: +31 (0) 252-660300...

  • Page 4: Warranty

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Warranty All parts and products are thoroughly inspected and tested from the time raw material is received our plant, until the product is completed. We guarantee that all products are free from defects in materials and workmanship for a period of one year from the date of shipment.

  • Page 5: Technical Assistance In The U.s.a

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Technical assistance in the U.S.A. If at any time during the installation a question arises that is not covered in this Installation Instruction, or with any other applicable documents referenced, feel free to call the OPW-ENGINEERED SYSTEMS –...

  • Page 6: Table Of Contents

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Table of Contents Operation Manual OPW Engineered Systems Disclaimer Warranty Approvals Technical assistance in the U.S.A. Table of Contents Specifications Electrical Specifications Inputs. Outputs. External environment reminder (see installation manual for details) Product Description.

  • Page 7: Table 4

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Power-up Normal operation. Function keys Bypass operation. Operational Function (blue) key Rack Function (Red) Key Safe disposal Function Key Loading A normal loading will end in one of the three possible situations. Example of a Loading cycle with ROM.
  • Page 8 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Registers Rack serial Reset counts Vehicle Id Probe status Rack status Channel status Date and time rating. Supplied accessories. Optional system accessories. Maintenance. Check Points. Troubleshooting.

  • Page 9: Specifications

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Specifications The Rack Monitor 88xxE is a loading rack monitoring system, detects and communicates a pending overfill condition to the loading rack control automation equipment by means of a normally open relay contact.

  • Page 10: Electrical Specifications

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Electrical Specifications Mains: Nominal min. input voltage : 90 Vac. Nominal max. input voltage : 250 Vac. Nominal input current : 50 mA @ 230 Vac Frequency : 50 / 60 Hz Nominal power consumption : 15VA.

  • Page 11: Inputs

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Inputs. Sensor Terminal J5 Pin 1~ 8 : all EN13922 compliant sensors. : all industry standard format overfill detection sensors . Two-Wire sensor (maximum eight) .

  • Page 12: External Environment Reminder (See Installation Manual For Details)

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Communications. Contact OPW FTG for availability. Miscellaneous. Optional sockets : expansion slots for additional functionality. Real Time Clock : precise trimmed Quartz real time clock. : clock is set to Greenwich Mean Time (GMT) SD Ram socket : Primarily used for Update Firmware...

  • Page 13: Sensors Types

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change The 88x0E monitor is designed to interface with the user by means of a large multi languages OLED Display and 20 full color Light Emitting Diodes indicators (LED) Clear and short messages will be shown on the OLED Display to explain the status of the overfill sensors, cabling and Rack monitor.

  • Page 14: Sensors And Grounding

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Sensors and Grounding. Before continuing describing the functionality of the rack monitor a short explanation of the sensors and ground verification. As mentioned above there are three industrial standard sensor principals. Thermistor sensors are not commonly used therefore the 88xxE is not supporting this type of sensor.
  • Page 15 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change The 885xE and 887xE rack monitor will communicate via the existing wiring. Initiation of the sensors is done during power-up of the sensors. Initiating a 12 compartment truck with 5-wire sensors can take up to 30 Sec.
  • Page 16 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change H72612N Page 16 of 55...

  • Page 17: System Operation

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change System operation. The purpose of the Civacon 88xxE Rack Monitor liquid level sensing system is to detect a liquid point level signal from a sensor mounted in compartments of a tank truck, or storage tank. The system provides an automatic signal to the rack automation equipment to shut-off the flow of liquid and warn of an impending overflow condition of a tank truck or storage tank.

  • Page 18: Relay Operation

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Relay operation This rack monitor is standard equipped with three relay outputs. The normally open Permit relay will switch if all sensors are dry AND a good ground connection is detected.
  • Page 19 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Front layout. GROUNDING INDICATORS GROUNDING ERROR INDICATOR BYPASS INDICATORS COMMUNICATION INDICATORS COMPARTMENT STATUS INDICATORS Figure 1 (Shown with cable glands. 88xxN models use rigid conduit) Above a the two models Rack Monitor, a 88x0 and a 88x1.

  • Page 20: Flash Pattern Table

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Flash pattern table: It is recommended to use a 88x0E rack monitor to minimize downtime in case of an error. The 88x0E rack monitor is equipped with a OLED display and 20 multi-color LED indicators to visualize the status of the Rack monitor, Tank truck and sensors.

  • Page 21: Ground Verification

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Ground verification The rack monitor will verify the impedance between pin 9 and 10 (including ground bolt) or if a clamp (model 7720) is used between the two jaws or the two pins of or ground plug Model 7620. Ground verification is set if the impedance is within the set boundaries.
  • Page 22 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change The 88xx rack monitor is designed to fulfill maximum safety. Therefore the rack monitor will try to detect all possible errors/faults when in EN13922 mode. One of the possible errors/faults is shorted channels / wires.

  • Page 23: Oled Display 88X0E

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Oled Display 88x0E. The 88x0E is fitted with an 2,7” Oled display with a temperature range between -45°C (-43°F) and +70°C (158°F) 12 multicolor Light Emitting Diode (LED 1~12) indicators are placed in the bottom window to indicate compartment status.

  • Page 24: Fault Visualization

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Fault visualization A rear view of the plug is shown in Figure 5. To indicate possible location of the fault E.g. The monitor detects a signal on pin 9 which is “out of range”. will appear on the screen with a “?”...

  • Page 25: Normal Operation

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Note: Tank-Truck shown at loading side for or Left-Hand-Drive. See Dip switch 7 for setting Normal operation. The main task of the 88xxE Rack Monitor is to provide a signal to the rack automation equipment to shut-off the flow of liquid as soon as a sensors in a compartment tank detect a liquid point level When the rack monitor is not used for 15 minutes it goes into sleep mode.
  • Page 26 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change General Specifications Outline dim. Function Key : Max. width x length x height = 20 x 65 x 15 mm Material Housing : Polycarbonate Max. capacitance : 15 pF Surface Resistance : <...

  • Page 27: Bypass Operation

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Bypass operation. Although it is not recommended, the 88xxE can also be bypassed in a faulty or wet sensor condition. If the monitor is NOT set to EN13922 then shorted between channels can be bypassed. Shorted channels to ground cannot be bypassed with the blue key.
  • Page 28 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change This stackable Bypass function differs from the bypass function of all our previous Rack Monitors. It will Bypass the occurred error instead of bypassing the Rack Monitor. For example compartment 2 of a tank truck equipped with 2-Wire sensors becomes wet during loading.
  • Page 29 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Rack Function (Red) Key The Rack Monitor 88xxis also shipped with a Red Function Key. This key should never be used for normal operation. This key is only needed as last resort to energize the permissive or ground verification relay.
  • Page 30 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Loading A tank truck with will be shown briefly as soon as the monitor has established type and in case of 5-wire sensors amount of sensors. If 2-wire sensors are connected then the amount of detected compartments are always 8 or 6 (depending on dip switch setting: see Figure 2 ).
  • Page 31 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Example of a Loading cycle with ROM. Symbol (any color) below means flashing Light Emitting Diodes A solid circle means LED indicator are solid on. Icons and compartments can also flash.
  • Page 32 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Figure 7 At this moment the function key can be used to accept and bypass the ROM. Place the function key as shown in the picture on the right at the middle bar.
  • Page 33 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change The indicator of the wet compartment (3) will be solid on and all remaining dry sensors indicators will flash red to emphasis the non -permit status of the monitor. Shown by the in the upper right corner Also the compartment on the display will flash as well as the second sensor icon on the bottom...
  • Page 34 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Table 4 Description Example e.g.  Unknown Accepted or valid Rejected or not valid Overfill sensor x-wire Overfill sensor >> 5-wire Overfill sensor Maintenance Unknown overfill Sensor ...

  • Page 35: Sensor Detection

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Faulty detected sensors. LED indication when a sensor fault (or more) is (are) detected Green indicators : all off Red indicator : all correct detected sensors are flashing and faulty sensor(s) is (are) continuous on If the fault is bypassed the rack monitor will revert to the state mentioned above with the faulty channels bypassed.
  • Page 36 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Since many Tank-Trucks are equipped with a ground bolt the 88xxE Rack Monitor will accept this automatically as a proper ground verification. Be aware that conform the EN13922 in combination with Five-Wire sensor(s) the earth verification is connected in series with the vapour recovery hose interlock switch Step 4.

  • Page 37: Firmware Upgrade

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Firmware upgrade. The 88xxE Rack monitor is built for the future therefore new updates to expand the functionality of this rack monitor can be expected. To upgrade your 88xxE rack monitor switch off all power to the rack monitor.
  • Page 38 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Civacon 8500/8800 Protocol Message Format: A1A2* Command_Text Where: = Start of Text = 02 Hex A1A2 = Address = 01-99 Hex Command Text = Character string including Command Code and associated parameters = End of Text = 03 Hex = Longitudinal Redundancy Check...

  • Page 39: Character Hex Value

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Command Code OS – Overfill Status Request Command: AA OS LRC. Reply Message: AA OS_C1C2C3C4C5 Where C1- C5 are defined in Tables 4~7. Where X indicates an asserted condition. Table 4 Character ‘C1’...

  • Page 40: Sensor 3

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Table 6 Character ‘C3 & C4’ Definition Character Hex Value Sensor 4 Sensor 3 Sensor 2 Sensor 1 Value Sensor 8 Sensor 7 Sensor 6 Sensor 5 <...

  • Page 41: Document: Operation Manual

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Command Code Request Command: AA VR LRC. Reply Message: AA VR_C1F1 Where = 0 (30 Hex) = No Vehicle Recognition System Detected = 1 (31 Hex) = Vehicle Recognition System Detected = 8 character serial number 1-Byte CRC Code...

  • Page 42: Date: 05 June 2024

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Modbus. Two register tables are available due compatibility with previous systems. Below the old and brief defined register table. This information will be available in register 20A to 21A. Serial communication is available via the RS485 port with a pre-settable baud-rate see Figure 2 Reg.
  • Page 43 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change The truck status register contains relevant data of the connected Truck. Truck Status Register 21A Register 20D Register 20E Register 20F Register 210 Register 211 Register 212 Register 213 Register 214...
  • Page 44 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Current Modbus 88xx Physical interface Figure 2 See Fout! Verwijzingsbron niet gevonden. for detailed dipswitch settings Registers Table 5 shows all Modbus registers. Registers that aren’t straight forward will be described in further detail later in this document. Reg.
  • Page 45 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Reset counts The reset counts keep track of the last reason why the Rack resets and the number of times the rack resets for each reason. Everything is stored as an unsigned 16-bit value. Register Reset reason Last reset reason for reset...
  • Page 46 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Probe status The probe status is given for any for each probe in the probe status registers. Register 71 Register 72 … Register 78 … Probe Probe Probe...
  • Page 47 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Rack status The rack status register has several status flags. Flag 0 is bit 0 of the register Flag Meaning Flag 0 5-wire detected Flag 1 2-wire detected Flag 2 Sensors are permissive...
  • Page 48 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change State Value Description Initial Initial value Channel good Channel is good Short to ground Channel is shorted to ground Open Channel is open Short to other channel Channel shorted to another channel Channel overloaded Channel is overloaded...

  • Page 49: Supplied Accessories

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change rating. The minimum Sil rating of the 88xx according IEC61508 is SIL1 which means a minimum risk reduction factor of 100.000-1.000.000 per hour at continuous operation The 88xx can be equipped with a secondary detection circuit with its own relay output to get a higher Sil rating.

  • Page 50: Maintenance

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Maintenance. When servicing the Rack Monitor 88xxE the following needs attention: Before maintenance the full installation must be shut down/off before proceeding. • Maintenance must be performed by authorized personnel only. •...

  • Page 51: Troubleshooting

    Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Troubleshooting. The following troubleshooting guide will give you first aid hands-on in solving most of the problems you can encounter. there are two types of problems. operational issues.
  • Page 52 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Condition Possible Cause Solution - The Rack Monitor 88xxE - The mains isn’t - Connect the mains. doesn’t turn ON connected. - Check if the main wiring is connected according to the installation instruction.
  • Page 53 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Annex A – Additional Electrical Drawings Ask OPW for different connection diagrams e.g. dual socket or junction box Annex B – Set clock The internal real time clock has been calibrated to the highest possible accuracy during production and set to GMT.
  • Page 54 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change Annex C - Recommended Spare Parts With the purchase of the Rack Monitor the OPW Engineered Systems recommends some spare parts to be purchased. Although this Rack Monitor 88xxE is designed with solid state lamps and a minimum maintenance spare parts are available.
  • Page 55 Rack Monitor 88xx Document: Operation Manual Date: 05 June 2024 Version: A.0 subject to change The following parts are also available: Part number Description Quantity EL00203-CRK Internally used connector kit BCU-BLUE Blue Function key (low level) BCU-RED Red Function key (high level) EL06802 SD-Ram Card 8800-BRK-14...

This manual is also suitable for:

Opw 8851nOpw 88 e seriesOpw 8870n

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