ABLE Ultima OPIR-5 Installation and operating instructions

Installation & Maintenance Instructions
Ultima® OPIR-5
Infrared Open Path Detector for Hydrocarbon Gas Applications
Reading
Tel: [phone] | Email: [e-mail]
Aberdeen
Tel: [phone] | Email: [e-mail]
Registered Address
ABLE Instruments & Controls Ltd
Cutbush Park, Danehill, Lower Earley,
Reading, Berkshire, RG6 4UT. UK.
Web
able.co.uk
E-commerce
247able.com

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.
MANOPIR5
Part No. MANOPIR5
Revision 2
Ultima® OPIR-5
Infrared Open Path Detector for
Hydrocarbon Gas Applications

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TABLE OF CONTENTS
ULTIMA® OPIR-5..........................................................................................................................I
INFRARED OPEN PATH DETECTOR FOR HYDROCARBON GAS APPLICATIONS...............I
QUICK START GUIDE.................................................................................................................6
System Mounting.................................................................................................................................... 6
Conduit Sealing ...................................................................................................................................... 7
Terminal Connections............................................................................................................................. 8
1.0INTRODUCTION.....................................................................................................................1
1.1Protection for Life ...................................................................................................................... 1
1.2Features and Benefits ............................................................................................................... 2
1.3Applications ............................................................................................................................... 2
1.4System Integrity Verification ...................................................................................................... 3
2.0PRODUCT DESCRIPTION.....................................................................................................4
2.1General Description................................................................................................................... 4
2.1.1Infrared Detection Principles ........................................................................................ 4
2.1.2Ultima OPIR-5 Detection Method ................................................................................. 4
2.1.3Measurement Scale...................................................................................................... 4
2.1.4Typical System Gas Cloud Measurements .................................................................. 6
2.1.5Control Electronics ....................................................................................................... 6
3.0INSTALLATION......................................................................................................................8
3.1Receipt of Equipment ................................................................................................................ 8
3.2Location Considerations ............................................................................................................ 8
3.3System Mounting....................................................................................................................... 9
3.4Installation................................................................................................................................ 10
3.5Conduit Sealing ....................................................................................................................... 11
3.6Terminal Connections.............................................................................................................. 11
3.6.1Terminal Block Operation ........................................................................................... 14
3.6.2Terminal Functions ..................................................................................................... 14
3.7Applying Power and Alignment................................................................................................ 15
3.7.1Start-Up Checklist....................................................................................................... 15
3.7.2Startup ........................................................................................................................ 15
3.7.3Alignment and Adjustment.......................................................................................... 16
3.7.4Response Test ........................................................................................................... 17
3.7.5Visible Light Filter ....................................................................................................... 17
3.8Operational Cautions............................................................................................................... 18
3.8.1Rapid and Massive Liquid Propane Releases............................................................ 18
3.8.2Solutions to Guard against These Situations ............................................................. 18
4.0OPERATION.........................................................................................................................19
4.1Using the Ultima OPIR-5 Detector Menus............................................................................... 19
4.2Menu Options .......................................................................................................................... 21
4.3Test “---”................................................................................................................................... 21

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4.4Setup “SE” ............................................................................................................................... 21
4.4.1Setup Options Sheet .................................................................................................. 23
4.5Flash Input “in”......................................................................................................................... 24
4.6Alignment/Adjustment “AJ” ...................................................................................................... 24
4.7Finish “Fi”................................................................................................................................. 24
4.8Maintenance ............................................................................................................................ 24
4.9Display and Fault Codes ......................................................................................................... 24
4.10LEL and ppm Negative Drift Faults ......................................................................................... 25
5.0TROUBLESHOOTING..........................................................................................................26
5.1Fault Codes ............................................................................................................................. 26
5.1.1F0 Excessive Negative Drift or High IR ...................................................................... 26
5.1.2F1 Partial Beam Block or Dirty Lens .......................................................................... 26
5.1.3F2 Alignment .............................................................................................................. 26
5.1.4F3 Beam Block ........................................................................................................... 27
5.1.5F4 Flash Erratic .......................................................................................................... 27
5.1.6F5 Setup Menu ........................................................................................................... 27
5.1.7F6 Low Supply Voltage............................................................................................... 27
5.1.8F7 Code Checksum.................................................................................................... 27
5.1.9F8 Failed Zeroing ....................................................................................................... 27
5.1.10F9 Gas Left ................................................................................................................. 27
5.1.11F10 Reset Short ......................................................................................................... 28
5.1.12F11 Unit Overheating ................................................................................................. 28
5.1.13F12 Optical Signal Variation....................................................................................... 28
5.1.14F13 Non-Volatile Memory........................................................................................... 28
5.1.15F14 AO Circuit ............................................................................................................ 28
5.1.16F15 Receiver Heater .................................................................................................. 28
5.1.17tF7 Source Heater ...................................................................................................... 29
5.2Other Troubleshooting Tips ..................................................................................................... 29
5.2.1Source does not flash................................................................................................. 29
5.2.2Receiver does not display startup sequence when power is applied......................... 29
5.2.3Receiver displays ]-[ during alignment ....................................................................... 29
5.2.4Receiver displays F1 or F3 after alignment................................................................ 29
5.2.5Receiver does not respond to the magnet ................................................................. 29
5.2.6Receiver AJ number went to 0 with no “A” on the display.......................................... 30
5.2.7Receiver displays information other than described .................................................. 30
5.2.8Source or Receiver will not move............................................................................... 30
6.0CUSTOMER SUPPORT.......................................................................................................31
7.0APPENDIX............................................................................................................................32
7.1Warranty .................................................................................................................................. 32
7.2Specifications........................................................................................................................... 33
7.2.1System Specifications ................................................................................................ 33
7.2.2Electrical Specification................................................................................................ 34
7.2.3Mechanical Specification ............................................................................................ 34
7.2.4Environmental Specification ....................................................................................... 35
7.2.5Approvals.................................................................................................................... 35
7.2.6Cable Requirements................................................................................................... 35
7.3Spare Parts and Accessories .................................................................................................. 36

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7.3.1Spare Parts................................................................................................................. 36
7.3.2Accessories ................................................................................................................ 36
7.4Engineering Documentation .................................................................................................... 37
8.0APPENDIX A........................................................................................................................38
8.1Split-Range Analog Output Option .......................................................................................... 38

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Table of Figures
Figure 1: Ultima OPIR-5 Detector................................................................................................................ 1
Figure 2: Indoor Gas Cloud ......................................................................................................................... 5
Figure 3: Outdoor Gas Cloud ....................................................................................................................... 5
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
Figure 9: Terminal Block Operation Diagram ............................................................................................. 14
Figure 10: Relay Contact Protection for AC/DC Loads .............................................................................. 15
Figure 11: Ultima OPIR-5 Source with Visible Light Filter.......................................................................... 17
Figure 12: Ultima OPIR-5 Detector Menu Tree .......................................................................................... 20
Figure 13: Outline Drawing......................................................................................................................... 37
Table of Tables
Table 1: Readings of Methane Gas Clouds 0-5000 ppm•meter Range...................................................... 6
Table 2: Readings of Methane Gas Clouds 0-5 LEL•meter Range............................................................. 6
Table 3: Receiver Wiring Terminal Locations........................................................................................... 13
Table 4: MSA Location ............................................................................................................................. 31
Table 5: Distances from Power Supply to Source and Receiver.............................................................. 35
Table 6: Distances from Receiver to Analog Output Load ....................................................................... 36

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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. Add the supplied bolt and washers; do not tighten until unit is fully
adjusted. If the bolt has been tightened and further adjustment is necessary, loosen the bolt
two turns and use a screwdriver between the pan-tilt assembly and arm to release the taper.
Pan Tilt Arm Assembl
y
with Fine
A
d
j
ustments Support Arm Assembly
Pan Tilt Base Assembl
y
with Fine Ad
j
ustments

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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. A conduit seal may not be required if installed in a Division 2
location.
MSA requires the use of a drain loop or conduit seal in the conduit to prevent moisture from
entering the unit housing. For installation in a Division 2 location using Division 2 wiring
methods, a drain loop or conduit seal may not be required. Consult Article 501 of the NEC for
details.
WARNING: The conduit entries should be sealed per the NEC 501.15 or Canadian
Electrical Code Handbook (Part 1, Section 18-154) for Division 1 installations.
WARNING: Unused cable entry holes must be sealed with an approved explosion-proof
stopping plug.
CAUTION: Acetic acid will damage metal components, hardware, and other components.
If damage results from the use of a sealant that outgases acetic acid such as a
room temperature vulcanizing sealant (RTV), the two-year warranty will be
void.
CAUTION: Consult the manufacturer for dimensional information on the flameproof joints
for repair.

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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). Recommended stripping length is 4/10” (10 mm) for push terminals, ½” (11 mm)
for screw terminals.
NOTE:Contact with printed circuit board (PCB) components should be avoided to prevent
damage by static electricity.