Lighthouse 1 CFM User manual

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Lighthouse Worldwide Solutions
1 CFM Mini Manifold(TM)
Operating Manual

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Copyright © 2008 by Lighthouse Worldwide Solutions. All rights reserved. No part of this
document may be reproduced by any means except as permitted in writing by Lighthouse
Worldwide Solutions.
The information contained herein constitutes valuable trade secrets of Lighthouse Worldwide
Solutions. You are not permitted to disclose or allow to be disclosed such information except as
permitted in writing by Lighthouse Worldwide Solutions.
The information contained herein is subject to change without notice. Lighthouse Worldwide
Solutions is not responsible for any damages due to use of the LMS program.
Mini ManifoldTM, LMS™, ECS™, ACU™, SIU™, AIU™, and MIU™ are trademarks of
Lighthouse Worldwide Solutions.
Microsoft®, Microsoft Windows™, and Excel™ are trademarks of Microsoft Corporation.
LWS Part Number 248083324-1 Rev 1

248083324-1 Rev 1 t-i
Table of Contents
About this Manual
Text Conventions ................................................................................................................ i
Additional Help ................................................................................................................. ii
Chapter 1 General Safety
Safety Considerations .................................................................................................... 1-1
Serviceability ................................................................................................................. 1-1
Shipping Carton ............................................................................................................. 1-1
Chapter 2 Introduction
Overview ........................................................................................................................ 2-1
Description ..................................................................................................................... 2-1
Accessories .................................................................................................................... 2-2
1 CFM Mini Manifold Specification ............................................................................. 2-2
Blower Specification ...................................................................................................... 2-2
Chapter 3 Getting Started
Initial Inspection ............................................................................................................ 3-1
Routine Servicing .......................................................................................................... 3-1
Features .......................................................................................................................... 3-2
Connections ................................................................................................................... 3-2
Communication Ports ........................................................................................ 3-3
DIP Switches ...................................................................................................... 3-3
Power ................................................................................................................. 3-3
Data .................................................................................................................... 3-3
Vacuum Pump/Blower ................................................................................................... 3-4
Chapter 4 Programming
General Information ....................................................................................................... 4-1
DIP Switches .................................................................................................................. 4-1
DIP Switch Settings .......................................................................................... 4-2

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GENERAL DEFINITIONS ................................................................... 4-2
Addressing ......................................................................................................... 4-2
Communicating with the Instrument ............................................................................. 4-4
Computer Port .................................................................................................... 4-4
Sensor Port ......................................................................................................... 4-5
RS-232 Communications ................................................................................... 4-5
RS-485 Communications ................................................................................... 4-6
Configuring with the MODBUS Protocol ..................................................................... 4-8
Setting the Real Time Clock .............................................................................. 4-8
Changing the Default Instrument Parameters .................................................... 4-8
Running the Instrument ............................................................................................... 4-10
Configuring a Sequence ............................................................................................... 4-10
Chapter 5 Final System Setup and Checks
Overview ........................................................................................................................ 5-1
Connecting Power .......................................................................................................... 5-1
Connecting the System Components ............................................................................. 5-2
Port Descriptions ................................................................................................ 5-2
Computer RS-232/485 IN Port .............................................................. 5-2
Computer RS-485 OUT Port ................................................................. 5-3
Sensor and Manifold Ports ..................................................................... 5-3
Connections: .................................................................................................................. 5-4
Sensor to Manifold ............................................................................................. 5-4
Communication Test ...................................................................................................... 5-5
Apply Power to the Instruments ........................................................................ 5-5
Connecting to an External Computer or Facility Management System ........................ 5-5
External Computer Connection ......................................................................... 5-5
RS232 Communications ........................................................................ 5-6
RS485 Communications ........................................................................ 5-6
LMS Express RT Starting Set Up .......................................................... 5-7
Chapter 6 Maintenance
Overview ........................................................................................................................ 6-1
Purge Test ...................................................................................................................... 6-1
Calibration ..................................................................................................................... 6-1
Return Shipping ............................................................................................................. 6-1
Appendix A MODBUS Register Map v1.39
COMM Settings ............................................................................................................ A-1
Supported MODBUS Commands ................................................................................. A-1
Register Map ................................................................................................................. A-2
Sensor Settings Registers .................................................................................. A-2

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Device Status .................................................................................................... A-4
Command Register ....................................................................................................... A-5
Alarm and Threshold Registers .................................................................................... A-6
Alarm Enable Registers .................................................................................... A-6
Enable Alarming for a Channel ............................................................ A-7
Threshold Setup Registers ................................................................................ A-8
Setting the Alarm Threshold Value ...................................................... A-9
Sequence Registers ..................................................................................................... A-10
Data Registers ............................................................................................................. A-10
Device Status Word ............................................................................ A-13
Data Enable Registers ..................................................................................... A-14
Data Type Registers ........................................................................................ A-14
Data Units Registers ....................................................................................... A-15
Appendix B Troubleshooting
Overview ........................................................................................................................ B-1
General Steps ................................................................................................................. B-1
Manifold ............................................................................................................. B-1
System Balancing .......................................................................................................... B-2
Basic Installation Parameters ............................................................................. B-2
Preliminary Checks ............................................................................................ B-3
Flow-Measure Longest and Shortest Runs ........................................................ B-3
Successful Flow Check ...................................................................................... B-4
Resolving Flow Issues ....................................................................................... B-4
Appendix C Limited Warranty
Limitation Of Warranties: .................................................................................. C-1
Warranty Of Repairs After Initial Two (2) Year Warranty: .............................. C-1
Index

Lighthouse 1 CFM Mini Manifold Operating Manual
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248083324-1 Rev 1 i
About this Manual
This manual describes the detailed operation and use of the Lighthouse
1 CFM Mini Manifold.
Text
Conventions
The following typefaces have the following meanings:
italics Represents information not to be typed
or interpreted literally. For example, file
represents a file name. Manual titles are
also displayed in italics.
WARNING: A
warning appears in a
paragraph like this and
warns that doing
something incorrectly
could result in personal
injury, damage to the
instrument or loss of
data.
boldface Introduces or emphasizes a term.
Courier font Indicates command syntax or text
displayed by the diagnostic terminal.
Bold Courier Indicates commands and information that
you type. You can use uppercase or
lowercase letters; in this manual,
commands are shown in uppercase.
Helvetica Italics Indicates a comment on a command or
text output.
Note: Notes stress an
importance or assist the
reader in a particular topic.

Lighthouse 1 CFM Mini Manifold Operating Manual
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Additional
Help
For more information about the Lighthouse 1 CFM Mini Manifold,
contact Lighthouse Worldwide Solutions:
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[phone] Sales and Support
[phone] Outside of USA
www.golighthouse.com
[email protected]

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248083324-1 Rev 1 1-1
1General Safety
These safety precautions pertain to the Lighthouse 1 CFM Mini
Manifold.
Safety
Considerations
The user or reader will find WARNINGS and CAUTIONS throughout
this manual. Familiarize yourself with the meaning of a warning before
proceeding. All warnings will appear in the left margin of the page
next to the subject or step to which it applies. Take extreme care when
performing any procedure preceded by or containing a warning.
There are several classifications of Warnings defined as follows:
• Laser - pertaining to exposure to visible or invisible laser radiation
• Operational - pertaining to correct operation of the instrument
Serviceability There are no user-serviceable parts contained within the Mini
Manifold. Opening these instruments by personnel other than those of
a Lighthouse authorized service provider will void the instrument’s
warranty.
Shipping
Carton
Retain the original shipping and packing materials to return the
instrument for calibration or servicing. Shipping the instrument in
other than factory approved packaging may subject your instrument to
shipping and handling damage and can void your warranty. If you need
a shipping container, contact Lighthouse Customer Service and one
will be provided for a nominal fee.
WARNING: The use
of adjustments or the
performance of
procedures other than
those specified within
this manual may result in
exposure to invisible
(infrared) radiation that
can quickly cause
blindness.
For more information or technical assistance, contact Lighthouse Sales
and Support at [phone].

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2Introduction
Overview This operating manual is an introduction to the Lighthouse Mini
Manifold System.
Description The Mini Manifold is an "air shield manifold" that uses a high-volume
vacuum pump, or blower, to pull sample air through all of the sample
tubes simultaneously. What this means is that the system maintains air
movement through each sample tube and reduces or eliminates
particulate "dropouts". It also provides a "shield" effect to prevent
cross-contamination between sample tubes by maintaining a vacuum
higher than that provided by the counter. This negates the effects of
leaks around the manifold’s sample tube, preventing particles from
entering the sample port. The required minimum flow rate of 3.75
CFM at ALL sample ports must be maintained in order for this
condition to be true.
Note: Information in
this manual may be
repeated from one
chapter to another. This
is done to prevent a need
to flip from one section
of the manual to another
repeatedly.
The particle counter (typically a SOLAIR) analyzes the selected air
stream for particles and reports this information to the Mini Manifold.
The Mini Manifold stores up to 8 particle count channels per record
and up to 250 records. It can supply this data to a PC running a
database or analysis software, such as LMS Express in real time or on a
cyclical basis. The system is designed to acquire accurate particle
counts from all locations and can be daisy chained.
Figure 2-1 1 CFM Mini Manifold and Blower

Lighthouse 1 CFM Mini Manifold Operating Manual
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Accessories Accessories that can be ordered to tailor the instrument to your needs
are listed below:
• Tube Adapters (optional - PushLok to Barb fitting)
• Isokinetic Sampling Probe 1.0 CFM (optional)
• Sample Tubing (optional)
• 0.1Pm @ 1.0 CFM Purge Filter Assembly with Tubing
(optional)
• Vacuum tubing per foot (optional)
• Cable per foot (optional)
1 CFM Mini
Manifold
Specification
Blower
Specification
Particle Counter used SOLAIR 1 CFM
Communication Modes RS-232 or RS-485 Modbus
Data Storage 250 records, rotating buffer
Supporting Software Lighthouse Monitoring System, LMS
ExpressRT, LMS ExpressRT+
Power +24VDC, 3A
Enclosure Stainless Steel, Anodized Aluminum
Dimensions 7.25" (l) x 5.0" (w) x 4.625" (h) [18.42 x 12.7
x 11.75 cm]
Weight 4.83 lbs (2.19 kg)
Operating Temp/RH 50° F to 104° F (10° C to 40° C) / 20% to 95%
non-condensing
Storage Temp/RH 14° F to 122° F (-10° C to 50° C) / Up to 98%
non-condensing
Table 2-1 1 CFM Mini Manifold Specifications
Blower Output 52 CFM (60Hz), 105 (50Hz)
Power Required 110VAC, 60 Hz, 5.6A maximum or
220VAC, 50 Hz, 9.3A maximum
Weight 29 lbs/13.2 KG (60Hz)
61 lbs/27.7 KG (50Hz)
Table 2-2 1 CFM Mini Manifold Blower Specifications

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3Getting Started
Initial
Inspection
Your Lighthouse instrument is thoroughly inspected and tested at the
factory and is ready for use upon receipt.
When received, inspect the shipping carton for damage. If the carton is
damaged, notify the carrier and save the carton and packing materials
for carrier inspection. Inspect the unit for broken parts, scratches, dents
and report any damage to your vendor.
If the carton is not damaged, keep it for reshipment when you return the
instrument for servicing. Shipping the instrument in other than factory
approved packaging may subject it to shipping and handling damage
and can void your warranty. If you need a shipping container, contact
Lighthouse Customer Service and one will be provided for a nominal
fee.
Routine
Servicing
The Lighthouse particle counter used with the Mini Manifold is a
precision measuring device manufactured to provide accurate particle
counting and sizing. It is protected by a two-year warranty when it is
calibrated and maintained on an annual basis. To protect this warranty
and insure many years of reliable service, the product must be serviced
only by a Lighthouse authorized service provider.
To return your Lighthouse product for calibration or servicing, please
contact Lighthouse Customer Service or visit our web site at
www.golighthouse.com/RMA to receive a Return Merchandise
Authorization (RMA).

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Features The Mini Manifold has the following features:
1. Communicates using MODBUS protocol.
2. Can store up to 250 data records.
3. Can be daisy chained in a multi-drop configuration using RS-485
communications ports.
4. Small footprint.
Connections
Figure 3-1 Connections on back of Mini Manifold
1. RS-232/485 IN port and RS-485 OUT port: Communication
ports.
2. RS-485 SENSOR Port: Connection port for SOLAIR 1 CFM
Airborne Particle Counter. This connects to the SOLAIR RS-232/
485 IN port
3. Power connector IN: +24VDC power supply input
4. DIP Switches (under plate): DIP switches 1-6 are for setting the
instrument address. Switches 7 and 8 are reserved for Factory use
and should remain ON. By default, the instrument is set to Address
1 (DIP Switch 1 is ON).
1
2
3
4
5
6

Getting Started
248083324-1 Rev 1 3-3
5. Vacuum Blower Connection: 1-inch OD Connection for an
external vacuum source.
6. Inlet Connection from Particle Counter: 1/4" ID, 3/8" OD tubing
is used to connect to the particle counter.
Communication Ports
The RS-232/485 IN port is a dual purpose connection. It is a hybrid of
the MODBUS over Serial standard incorporating both short distance
single instrument RS-232 and long distance multi-point RS-485.
The RS-232 connection is provided for quick simple cable connections
from a single unit to a standard PC COM port.
WARNING: When
connecting multiple
instruments on an RS-
485 communications
chain, make sure to
connect OUT ports only
to IN ports and use only
standard 8-wire CAT5
cable. Do NOT connect 2
IN ports together - this
will damage the unit and
void the warranty.
The RS-485 connection is provided for industrial applications with
multiple devices on the same bus. Both connectors allow easy
connections using standard CAT 5 patch cables commonly used for
office LANs. Connecting the instrument to a PC via RS-485 requires
an RS-485 to 232 converter, cables, connectors and terminator. Please
contact your Lighthouse Sales Representative for the LWS RS-485
converter kit.
For a detailed discussion of the MODBUS registers and commands,
please see Appendix A.
DIP Switches
DIP switches 1-6 are used for setting the instrument address for RS-485
daisy chain configurations and the Communications Mode.
Switches 7 and 8 are used for factory use and should remain ON.
When DIP switches 1-6 are OFF, the address is 0, which puts the
instrument into Broadcast mode. Broadcast mode should not be used
for this application.
Power
The Mini Manifold uses an external power supply rated at +24VDC at
3A.
Data
Data is stored on the Mini Manifold in a 250 record rotating data buffer.

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Data can be uploaded real time to LMS Express RT, LMS Express RT
Plus or to a Lighthouse Monitoring System. Real time systems allow
monitoring of the instrument counts on a minute-by-minute basis or for
a specified sample time.
For specific information on setting up and running the 1 CFM Mini
Manifold and SOLAIR system, refer to the LMS Express RT, RT+ or
LMS Operating Manuals.
Vacuum
Pump/Blower
The 1 CFM Mini Manifold uses a Vacuum Pump (Blower) to supply a
continuous vacuum to the Manifold, which keeps air flowing through
all ports and keeps them and the interior of the manifold free of
particles.
Figure 3-2 Blower IN and OUT Ports
The Blower must be attached to the Mini Manifold before operating the
manifold or particle counter. Refer to Figure 3-2 and install the
Adapter and Barb fitting to the Blower IN port. Refer to Figure 3-1 and
Figure 3-2 to connect sample tubing and blower tubing to the Mini
Manifold.
Sample tubing runs should be in place prior to setting up the Mini
Manifold, should not exceed 600 feet, total length of all runs and no
single run should exceed 100 feet. There should be no kinks or sags in
any run and angles should greater than 90-degrees.
Connect to Manifold
Vacuum Port
Blower IN
Blower OUT

Getting Started
248083324-1 Rev 1 3-5
The blower input tubing should be limited to ten feet as well as the
exhaust tubing (if desired to ’port’ exhaust outside of blower location).
Vibration dampening pads should be used if the blower will be installed
where it may transmit vibrations into the particle counter; this will
prevent spurious counts.
Refer to “Final System Setup and Checks” on page 5-1 and
“Troubleshooting” on page B-1 for detailed information about
connections and tubing runs.

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