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.

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Receiver Wiring Terminal Locations
9 10 11 12 13 14 15 16
+24V
COM
0-20mA L
COM
0-20mA P
COM
RST
COM
8 MOD1- Modbus1- Modbus2- MOD2- 17
7 MOD1+ Modbus1+ Modbus2+ MOD2+ 18
Normally
De-
energized
Normally
Energized Normally Energized
Normally
De-
energized
6 A2 Alarm NO Alarm NC Fault NO Fault NO FLT1 19
5 AC Alarm C Alarm C Fault C Fault C FLTC 20
4 A1 Alarm NC Alarm NO Fault NC Fault NC FLT2 21
3 W2 L Warn
LEL•m NO Warn LEL•m NC Warn ppm•m NC Warn ppm•m NO W2 P 22
2 WC L Warn
LEL•m C Warn LEL•m C Warn ppm•m C Warn ppm•m C WC P 23
1 W1 L Warn
LEL•m NC Warn LEL•m NO
Warn
ppm•m NO Warn ppm•m NC W1 P 24

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Terminal Block Operation
To connect wiring to the terminal block, insert a screwdriver into the orange tab and press
down, opening the terminal (see figure below). Insert the wire into the terminal and
release the orange tab, clamping the wire in the terminal. Check the clamp by GENTLY
tugging the wire to ensure it is locked in. Make sure that the terminal clamps on to the
wire, not the insulation.
Terminal Block Operation Diagram
The push terminal block is designed to accept 24 AWG to 16 AWG (0.2 mm2 to 1.5 mm2)
stranded or solid-wire. The optional screw terminal block accepts 26 AWG to 14 AWG (0.14
mm2 to 2.5 mm2 ) 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.

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Startup
Before applying power to the system for the first time, all wiring connections should be
checked and the housing cover securely fastened.
Display Sequence on Power Up
Display Duration (s)
0 0 0 1
8.8.8. (Test all segments) 2
blank 3
Software revision letter 2
SU (Start Up) 120
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●m or 100 ppm●m. Since HART, Modbus,
and 4-20 mA outputs have more resolution, the least significant digit of the displayed value
might not agree with that of other outputs due to rounding error.

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Alignment/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 performance. If there is gas present, try
setting-up the Ultima OPIR-5 Detector on a breezy day, as this dissipates the gas.
1. It is recommended that two people are involved in aligning the Extended Range Unit.
One person should be at the Source and one person should be at the Receiver. An
alignment scope is helpful but not necessary. Otherwise follow the general Alignment and
Adjustment instructions.
2. At the Source, check the four screws that hold the unit to the pan-tilt assembly. Verify
that the back two screws have been tightened but that the front two have not. On the
pan-tilt assembly, verify that the front and back fine adjust screws are flush with the
assembly surface, to allow full movement of tilt. If necessary, use a 2.5 mm hex wrench
to adjust the screws. Use the housing sights to aim the unit at the center of the Receiver.
Align the notch and pin of the sights with the Receiver center.
3. At the Receiver, check the four screws that hold the unit to the pan-tilt assembly. Verify
that the back two screws have been tightened but that the front two have not. On the
pan-tilt assembly, verify that the front and back fine adjust screws are flush with the
assembly surface. Use the housing sights to aim the unit at the center of the Source.
Verify that the Receiver display is 0. Put the magnet on the upper right edge of the
display. The display will change from 0 to rst, ---, SE, and AJ (Adjustment). Remove the
magnet when AJ appears. The Receiver will display “A” with an AJ value from 0 to 99 or
“]-[“ if no Source signal is detected. Note that in 60 minutes, the alignment mode will time

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out and return to run mode. If this occurs, reapply the magnet and return to alignment
mode.
4. At the Receiver, lightly tighten the front fine adjust screw until it bottoms out against the
internal tilt lever. Slowly make a small turn to tighten the screw and lower the front of the
Receiver. Wait a few seconds for the AJ number to settle. Continue making small turns,
waiting after each turn for the AJ number to settle. Once the AJ number begins to
decline, back out the front fine adjust screw until it is flush with the assembly surface.
Lightly tighten the back fine adjust screw until it bottoms out, and then slowly make a
small turn to further tighten it. Wait a few seconds for the AJ number to settle. Continue
until the AJ reaches its maximum and begins to decline. Back out the back fine adjust
screw.
5. Secure the two front mounting screws. Verify that AJ is reduced by 2 or less (increase of
any amount is acceptable).
6. Adjust the Receiver pan for maximum AJ. Slowly tighten the nut at the bottom of the
pan-tilt assembly while holding the left side of the Receiver. Verify that the AJ is reduced
by 2 or less (increase of any amount is acceptable).
7. With the Receiver secure, verify that the AJ is comparable to typical values listed below.
8. At the Source, repeat steps 3 through 6 to adjust its position, while checking the AJ
number at the Receiver.
9. With the Source secure, verify that the AJ is comparable to typical values listed below.
Range 20 m 30 m 40 m 50 m 60 m 70 m 80 m 90 m 100 m
AJ value 72 to 67 65 to 60 59 to 54 53 to 48 49 to 43 45 to 38 43 to 35 39 to 32 35 to 30
Typical AJ Values
10. At the Receiver, put the magnet on the upper right edge of the display to exit alignment
mode. The unit will display a flashing AC and begin zeroing the gas reading. Once
zeroing is complete, the unit will display gas concentration. System alignment is
complete.
NOTE:The basic mounting arm offered by MSA to wall mount the system follows similar
alignment instructions, with the difference being the lack of a fine adjust.
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).
Follow the instructions listed on the films.

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1.0 Introduction
1.1 Protection for Life
MSA’s mission is to benefit society by providing solutions through industry leading
safety products, services, and systems that save lives and protect capital
resources from the dangers of hazardous flames, gases, and vapors.
This manual provides instruction for installing and operating MSA’s Ultima OPIR-5
Detector for combustible gas detection. It should be read in full and the information
contained herein understood before attempting to place the system in service.
The safety products you have purchased should be handled carefully and installed,
calibrated, and maintained in accordance with the respective product instruction
manual. 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.
WARNING: Toxic, combustible, and flammable gases and vapors are dangerous.
Extreme caution should be used when these hazards are present.
Do not open when an explosive atmosphere is present.
Potential electrostatic charging hazard. Use only a damp cloth for
cleaning.
CAUTION: Read and understand this instruction manual before operating or
servicing the equipment.
Seal all conduits within 18 inches of enclosure.
Use wire suitable for 16°C above ambient for the Receiver and 32°C
above ambient for the Source.
Figure 1: Ultima OPIR-5 Detector

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1.2 Features and Benefits
The advantageous features and benefits of the Ultima OPIR-5 Detector include:
Performance certified: only open path detector to meet multiple agency
performance requirements on both the LEL•meter and ppm•meter scales.
Single detection beam: eliminates drift and false alarms.
Dual detection ranges (ppm•meter & LEL•meter): sensitive to low-level
leaks.
Unitized design - digital readout, 4 relays and two 4 to 20 mA outputs:
wide variety of outputs.
Type 4X, IP66/IP67 weatherproof rating: highly durable unit.
Fail-to-safe operation: alerts user to fault in operation.
Automatic gain control: compensates for dirty optics, rain, and fog.
Power supply input reversal protection: protection against miswiring
damage.
Dirty Window delay and Beam Block delay: reduces maintenance and
false alarms.
1.3 Applications
This is a partial list of applications suitable for the Ultima OPIR-5 Detector:
Compressor stations
Drilling and production platforms
Fence line monitoring
Fuel loading facilities
Gas turbines
LNG/LPG processing and storage facilities
Petrochemical plants
Tank farms
Wastewater treatment

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1.4 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
Signaling or output devices
Accessories connected to field and signaling devices
After the initial application of power and any factory specified warm-up period to the
safety system, verify that all signal outputs to and from devices and modules, are
within the manufacturers’ specifications. Initial alignment, alignment checking, and
testing should be performed according to the manufacturers’ recommendations and
instructions.
Proper system operation should be verified by performing a full, functional test of
all component devices of the safety system, ensuring that the proper levels of
alarming occur. Fault detection should be verified.
Periodic Testing of Field Devices
Periodic testing or alignment should be performed per the manufacturers’
recommendations and instructions. Testing and alignment procedures should
include, but not be limited to:
Verify zero reading
Verify gas reading by applying a Test Gas Film
Verify integrity of all optical surfaces and devices
When testing produces results outside of the manufacturers’ specifications, repair,
or replacement of the suspect device(s) should be performed as necessary. Test
intervals should be independently established through a documented procedure,
including a verification log maintained by plant personnel or third party testing
services.
Periodic System Verification
The following system verifications should be performed at least annually:
Wiring, terminal connections and stability of mounting
Proper system operation verified by performing a full, functional test
of all component devices of the safety system, ensuring that the
proper levels of alarming occur
Fault circuit operation

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2.0 Product Description
2.1 General Description
The Ultima OPIR-5 Detector is a hydrocarbon gas detector (Figure 1). The system
consists of a Source and a Receiver. Both units are calibrated at the factory and
need no further alignment. The operation of the Ultima OPIR-5 Detector can be
checked by placing a Test Gas Film in front of the Receiver. The system requires
only a periodic cleaning of the windows to assure dependable performance, and is
recommended prior to zero check, test gas, and optical integrity testing. The Ultima
OPIR-5 Detector continuously monitors hydrocarbon gases. The gas detection
range of a Receiver calibrated for methane is 0 to 5,000 ppm•meter and 0 to 5
LEL•meter while that for propane it is 0 to 2,000 ppm•meter and 0 to 1 LEL•meter.
The Receiver provides two 4 to 20 mA analog signals, one proportional to
ppm•meter and the other to LEL•meter. Alarm and Fault relays, split range (A/O-
ppm), Modbus, and HART outputs are optional.
The Ultima OPIR-5 Detector is easily aligned using the digital display and
adjustable mounting arms, therefore does not require any bulky setup equipment
such as digital volt meters and handheld alignment aids. For setups that require the
distance from the Source to the Receiver to be greater than 100 meters, MSA
offers an optical alignment scope that makes the initial alignment easier.
2.1.1 Infrared Detection Principles
Most gases absorb infrared radiation. Hydrocarbon gases absorb infrared radiation
at specific wavelengths but with different degrees of absorption. Absorption of the
radiation follows the Beer-Lambert Law, which states that the transmittance (T) of
radiation through an absorbing medium decreases exponentially by the product of
the absorption coefficient (A), the concentration (C), and the path length (L):
T = exp(-ACL)
Here T0is the transmittance of light containing no absorbing medium.
2.1.2 Ultima OPIR-5 Detection Method
The Ultima OPIR-5 Detector uses a single beam, dual wavelength method of
infrared absorption detection. The gas absorbs one wavelength but not the other,
which is the reference wavelength. By comparing the signals from these two
wavelengths, the detector measures gas concentration. The reference wavelength
is chosen to compensate for interferences that can otherwise occur from
atmospheric variation, such as humidity, rain, dust, snow, fog, steam, and
temperature. This method of detection comes under what is commonly known as
the non-dispersive infrared (NDIR) absorption principle.
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 in concentration meter. The Ultima OPIR-5 Detector reports

Ultima OPIR-5 Detector
5
No Wind
concentrations in the ppm•meter range (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. The Alarm setpoint should
be equal to or less than the reading for a gas concentration of 60% LEL at the
target gas cloud length.
Typical gas cloud configuration:
Figure 2: Indoor Gas Cloud
Figure 3: Outdoor Gas Cloud