Pinssar Dpmra01.a User manual

PIN-M-01 DPM Reader User Manual DPMRA01.A

DPM READER

User Manual for Model

DPMRA01.A

Page 2 of 24

Document Change Record

Revision

Date

Change Note

1.0

22/03/2016

Release

2.0

09/05/2016

Add operational temp range & connectivity compliance

to AS/NZ60950-1 Page 6/22

3.0

9/8/2017

Updated to current design

4.0

30/10/2019

Minor updates and additional Pictures

4.0

(re-issue)

16/12/2019

Add “Unit is NOT intrinsically safe”, and add accuracy

disclaimer.

Notice:

The information contained in this document is subject to change without notice.

While every care is taken to ensure the accuracy of the information and statements

made in this document, Pinssar (Aust) PTY LTD, or any other associated or related

company, makes no representation or warranties about its accuracy, reliability,

completeness or suitability for any particular purpose and disclaims all responsibility

and all liability (including without limitation, liability in negligence) for all expenses,

losses, damages (including indirect or consequential damage) and costs which you

might incur as a result of the information and statements made in in this document

being inaccurate or incomplete in any way and for any reason.

translation without prior permission is prohibited except as allowed under copyright

laws.

 
Copyright © Pinssar (Aust) Pty Ltd 2019. The PINSSAR logo is a registered trademark of Pinssar Pty Ltd 
 Page 3 of 24 
Contents 
1General..........................................................................................................5 
2Parts provided................................................................................................6 
2.1 Parts not supplied with this DPM Reader ........................................................6 
3Cautions and Warnings..................................................................................6 
3.1 Important .........................................................................................................6 
3.2 Caution............................................................................................................6 
3.3 Mains Voltage..................................................................................................7 
3.4 Laser ...............................................................................................................8 
3.5 Earthing...........................................................................................................8 
4System Overview...........................................................................................8 
5Scope of Installation Manual..........................................................................9 
6Installation....................................................................................................10
6.1 Unpacking the DPM Reader..........................................................................10
6.2 Wall or vertical flat surface mounting.............................................................11
6.3 AC mains dedicated wall socket installation..................................................14 
6.4 Fitting SIM card for DPM Reader...................................................................14
6.5 Connecting the DPM Reader to the AC Mains supply...................................15 
6.6 Connecting the RJ45 Ethernet cable with gland............................................15
6.7 DPM Reader Enclosure Front Door Access ..................................................16
6.8 Soft Start Power ON......................................................................................16 
6.9 Confirm Reader is Operating.........................................................................17
6.10 Connecting the Reader to a Laptop or Network .........................................17
6.11 Enabling and Disabling the Internal Battery ...............................................17 
6.12 External Bulkhead connector Dust Caps....................................................18 
6.13 DPM Reader System “OFF” Battery Charger “ON” ....................................18
7De-installation and Transportation of DPM Reader......................................18
8User Maintenance........................................................................................18
8.1 Regular Interval Servicing..............................................................................18
8.2 Safety Control Level’s (SCLs)........................................................................19
8.3 Servicing Interval Table.................................................................................20
8.4 External high humidity and dust filter (05-0795) maintenance.......................20

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8.4.1 05-0795 External High Humidity Filter Removal .............................20

8.4.2 Draining filter housing .....................................................................21

8.4.3 Cleaning fine mesh metal filter (100976).................................................22

8.5 Internal clean air filter cartridge replacement.................................................22

8.5.1 100974 Replacement Filter Internal........................................................22

8.6 Cyclone Filter Maintenance...........................................................................23

Page 5 of 24

1 General

The DPM Reader model number DPMRA01.A is designed for vertical mounting

onto a flat surface. The Reader is a stand-alone device with USB, Ethernet and

Wireless connectivity. Limited AC Mains fail battery backup is provided using an

internal Lithium Ion Phosphate battery.

FIGURE 1-PICTURE OF THE DPM READER

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2 Parts provided

Part Number

Description

Qty

DPMRA01.A

DPM Reader 655Hx600Wx250D c/w S/S

Enclosure

98-1149

USB Jumper cable (900mm length)

90545

Ethernet Jumper cable CAT5e (1.5m length)

98-1150

Ethernet Cable Gland

98-1353

AC Mains power cord (1m length) Aust. plug

112693

Door Access Key (Square profile)

100969

PTFE Tape

Installation Manual

Calibration Certificate

Warranty Certificate

Tech Service Qualification Statement

Terms & Conditions of Sale-Pinssar Holdings

2.1 Parts not supplied with this DPM Reader

•Wall mounting bolts (~ 10mm x 4)

3 Cautions and Warnings

3.1 Important

The DPM Reader is NOT Intrinsically Safe

Do not operate or maintain the DPM Reader in any environments classified as

hazardous as it may ignite flammable gases.

3.2 Caution

Please read the installation manual thoroughly before installation. Incorrect operation

could result in death or serious injury.

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The DPM Reader is considered a two person lift packed or unpacked. Care must

be taken carrying the unit as it has at its core, sensitive electronic measuring

equipment which could be damaged if the unit is dropped from any height or

excessively vibrated in transportation.

Installation should be left to trained personnel who have been sufficiently briefed on the

installation requirements and aspects of this DPM Reader.

Do not install the DPM Reader in any position of direct sunlight, corrosive environments

or high temperatures in excess of the stated operational temperature range. Please

ensure the moisture and dust environment of the installation is in accordance with the

stated IP rating of the DPM Reader.

The Reader contains a single internally mounted Lithium Iron Phosphate battery pack

with a rating of 12.8VDC 6.4AH (81.9WH).

Any devices that connect to the data ports must comply with clause 4.7 of AS/NZS

60950.1.

The DPM Reader is to be installed and operated in an environment with a minimum

temperature of -10°C and a maximum temperature of +50°C.

3.3 Mains Voltage

All electrical work should be carried out in accordance with the state, federal or

applicable national electrical wiring codes and regulations.

The AC Mains electrical point into which the Reader is to be connected, must be

installed by a qualified electrician. The provided AC mains cable with special connector

interface for termination into the enclosure is one (1) metre in length and therefore we

recommend that the power socket dedicated to the DPM Reader should be installed

within 500mm of the left-hand side ofthe enclosure. The socket should be wired through

a suitable circuit breaker via an RCD device.

Two labelled isolation switches are provided on the left-hand side of the DPM Reader.

One is to isolate the AC mains, the other is to isolate the internal battery DC source

during service or whilst being transported. An additional LED illuminated low profile

power switch is located on the same side as the isolator switches, labelled POWER

which powers the internally mounted PLC and electronics.

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Access into the DPM Reader is intended for suitably qualified electrical service

personnel ONLY. Although an access key is provided with the DPM Reader, there

is no requirement to open the hinged door on the reader whilst installing the

reader.

Please be aware that if the access door is opened for any reason, DIRECT

exposure to live AC Mains contact points will be a very real danger.

3.4 Laser

The internal measurement laser scattering chamber houses a Class 3B laser.

There is no need to open the enclosure to gain access to the laser scattering

measurement chamber during the installation process, however should the laser

scattering measurement chamber be dissembled in the field for any reason, you may

be exposed to the laser beam causing possible injury to the unprotected eye. Avoid

visual contact with the laser beam.

3.5 Earthing

The mains earth is connected via the mains cable and respective earth pin.

4 System Overview

The PINSSAR DPM Reader is a stationary/fixed position near-real time diesel emission

monitoring apparatus.

The DPM Reader uses a laser light scattering photometer to measure the concentration

of diesel particles in a known volume of air. The reader enclosure is designed to be

vertically mounted on a flat surface such as a wall.

Page 9 of 24

Built into a 316-grade sloping roof stainless steel enclosure 655mm in height,

600mm in width and 250mm in depth with front door access for serviceability, the

DPM Reader is built for indoor operation in road/rail tunnel, loco/bus/plant/heavy

vehicle service depots, and underground mining environments.

The measured sample air intake is located at the bottom of the enclosure. Although

diesel particulate concentration levels may vary slightly with respect to height, we

recommend the enclosure is mounted at least 1 metre (from the bottom of the enclosure)

above the ground level to reduce proximity to dust on floors and general grime. This

also facilitates ease of serviceability.

The reader emission concentration measurements can be sent real time to a server via

an IP Network for evaluation and storing.

An Ethernet socket located on the left-hand side of the Reader facilitates connectivity

to a wired LAN, alternatively wireless connectivity is provided via the router and antenna,

which is configurable for Wi-Fi or cellular wireless networks.

The DPM Reader operates in measurement cycles.

The measurement cycle draws external air through a cyclone filter which filters

particulates in terms of size. The sample air is then heated to vaporise lower levels of

moisture and then passed through the measurement chamber.

Each measurement cycle is then followed by a clean air (particle free) flush through the

sampling air lines and measurement chamber where a reference zero reading is

obtained.

This data is fed into the on-board PLC and then communicated to a server via a

nominated IP network.

5 Scope of Installation Manual

The purpose of this document is to provide detailed instructions on the installation of the

PINSSAR DPM Reader enclosure.

The DPM Reader is considered a two person lift packed or unpacked.

Designed for fixing to a vertical flat surface the Reader has a top and bottom mounting

flange with mounting slots to accommodate suitable wall mount fasteners ~10mm).

The fasteners are not supplied with the Reader as in each application the wall type may

be different and consideration must be given to the strength, surface finish, hang weight

and then suitable fastener types.

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The Reader is operational once the isolation switches are turned to the “ON”

position and the PLC LED illuminated power switched pressed on. Please note

that the press button LED will only illuminate after approximately 15

seconds. Refer to section 6.8 for the LED illumination Vs status table.

6 Installation

6.1 Unpacking the DPM Reader

Open the box packaging with caution removing the user manual and parts and checking

these against the supplied parts check list.

FIGURE 2-READER PACKAGING

A visual inspection is then advised to ensure the DPM Reader has not sustained

transportation damage. The sloping roof enclosure should be void of dents or scratches

and the top and bottom mounting flanges straight and un-bent for mounting against a

flat surface. The Reader can be rested prior to installation on its back with the access

door facing up. Care must be taken not to damage the termination connectors, switches

and or air-intake and exhaust air apertures during removal or mounting.

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6.2 Wall or vertical flat surface mounting

Do not install the DPM Reader in any position of direct sunlight, corrosive

environments or high temperatures in excess of the stated operational temperature

range.

In areas of relatively high humidity ensure the optional external moisture filter is fitted.

Please ensure the moisture and dust environment of the installation is in accordance

with the stated IP rating of the DPM Reader.

The DPM Reader is not intrinsically safe. Do not operate or maintain the DPM Reader

in any environments classified as hazardous as it may ignite flammable gases. The

Reader contains a single internally mounted Lithium Iron Phosphate battery pack with

a rating of 12.8VDC 6.4AH (81.9WH).

The Reader can be either mounted directly for a vertical surface or hung from suitably

installed mounting points.

Ensure that the wall or vertical flat surface against which this DPM Reader is to be

installed is structurally strong enough to hang the weight of the DPM Reader (32Kg).

We recommend a mounting height of > 1 metre to the base of the DPM Reader

enclosure for ease of access and distance to dust and grime on the floor.

The wall or vertical surface should also not be prone to excessive high vibration or

flooding.

The enclosure has two mounting holes in the top flange and two in the bottom flange.

The vertical and horizontal dimensions between the four centres are as illustrated in

Figure 3. The depth measurements to determine mounted profile areillustrated in Figure

4. Use four appropriate ~ 10mm fasteners to fasten the enclosure against the wall or

flat vertical surface. Please note: Fasteners are to be sourced separately by the

installer/user and are not supplied with the DPM Reader.

Page 12 of 24

FIGURE 3-ENCLOSURE MOUNTING HOLE POSITIONS –FRONT VIEW

FIGURE 4–ENCLOSURE MOUNTING HOLE POSITION –SIDE VIEW

We recommend the use of a spirit level to ensure the enclosure is mounted true to

vertical. This however is not for functional reasons, purely aesthetic and helps to keep

the access door hinged without unbalanced gravitational forces swinging the door either

open or closed.

Page 13 of 24

FIGURE 5-DPM READER -RIGHT HAND SIDE

FIGURE 6-DPM READER -LEFT HAND SIDE

Cyclone inlet and

Pressure Relief Valve

Page 14 of 24

6.3 AC mains dedicated wall socket installation.

The AC Mains wall or surface mount socket should be installed within 500mm of

the left hand side of the enclosure (once mounted) facing it from the front.

The AC Mains electricalpoint into which the reader is to be connected, must be installed

by a qualified electrician. The provided AC mains cable with special connector interface

for termination into the enclosure isone (1) metre in length and therefore we recommend

that the power socket dedicated to the DPM Reader should be installed within 500mm

of the left-hand side of the enclosure. The socket should be wired through a suitable

circuit breaker via an RCD device.

6.4 Fitting SIM card for DPM Reader.

The DPM Reader has a SIM reader located as illustrated in the Left Hand View of the

Reader. Before connecting the AC Mains cord to the Mains Input socket on the

enclosure, ensure that the allocated SIM card for the internally installed cellular router

is inserted and locked into the provided socket.

The SIM orientation is as per the diagram in Figure 7.

CAUTION: Do not insert the SIM card after the DPM Reader has been powered on via

either one or both isolation switches.

FIGURE 7-SIM CARD SLOT IN LEFT HAND SIDE

Ensure the installed SIM is inserted deep enough into the provided socket that its top

edge is locked flat to the surface of the socket.

To remove the SIM card, press the visible top edge of SIM card in the socket and

release. The spring-loaded SIM card should jump out of the socket by about 5mm.

Page 15 of 24

Screw the provided dust cap back onto the bulkhead connector once installed or

de-installed.

6.5 Connecting the DPM Reader to the AC Mains supply

Ensure that both the Battery and AC Mains isolation switches on the DPM Reader are

in the “OFF”position.

Terminate the AC power cord supplied into a local plug using the connection diagram

in Figure 8. Con1 is the plug which plugs into the Mains Input socket –see the Left Hand

Side View of the Reader. Termination of the plug is to be done by a suitably licenced

electrician in accordance with regulations.

FIGURE 8-MAINS POWER PLUG WIRING

Using the AC power cord, connect the AC power cord plug to the socket on the DPM

Reader enclosure marked AC Power input and then connect the country specific plug

to the AC Mains wall mount socket.

Switch the wall socket “ON” and then switch the AC Mains and Battery isolation switches

to “ON”.

6.6 Connecting the RJ45 Ethernet cable with gland

The Reader comes packed with a Cat.5e harsh environment gland. This gland must be

installed on to the ethernet cable to ensure the Reader maintains an IP64 rating. The

instructions in Figure 9 and Figure 10 give guidance on installing the gland on to a

standard Cat.5 Ethernet cable.

Page 16 of 24

FIGURE 9–FITTING THE RJ STOP

FIGURE 10 -INSTALLING THE GLAND

6.7 DPM Reader Enclosure Front Door Access

There is no requirement at the installation stage to access the DPM Reader via

the front door. Access is restricted to qualified service personnel only and is

sealed accordingly with security stickers.

6.8 Soft Start Power ON

Depress the POWER ON button located adjacent to the Mains Input connector on the

DPM Reader enclosure.

Page 17 of 24

This will initiate the PLC start up procedure.

Once depressed it will take approximately 15 seconds for the press button switch

LED to illuminate. Consult the following table to identify the system status via the LED

indicator.

LED State

STATUS

GREEN - solid

AC Supplied –system idle

GREEN - flashing

AC Supplied –system sampling

RED - solid

Battery Backup –system idle

RED - flashing

Battery Backup –system sampling

6.9 Confirm Reader is Operating

Once the Reader has been switched on, wait approximately 5 minutes to confirm that

the reader is operating by observing the LED power light and listening for the machine

to complete a cycle. During sampling, the LED power light will blink green. The internal

blower, used to pull ambient air into the sample chamber, will being to operate. The

blower can be heard spinning by listening from the outside of the enclosure (there is no

requirement to open the enclosure to hear the blower functioning). Confirm for two

sampling cycles to ensure that the Reader is functioning correctly. Once functionality

has been confirmed, the reader is now ready to connect to a laptop or network.

6.10 Connecting the Reader to a Laptop or Network

For connecting the DPM Reader to a laptop or network, please refer to the Pinssar DPM

Monitoring System Dashboard User Manual, or the Pinssar DPM Monitoring System

Software Installation Manual.

6.11 Enabling and Disabling the Internal Battery

The internal battery is required to provide battery backup during loss of power. Once

the DPM Reader is installed, turn both the AC Mains and battery isolation switches to

“ON” and leave them both in the “ON” position. Should the DPM Reader enclosure need

to be moved or disconnected from the AC Mains, it will be necessary to isolate the

battery via the battery isolation switch. The isolation switches are used to de-energise

power to the electronic circuitry.

NOT isolating both the AC and DC power to the electronic circuits during service or

transportation may risk damage to the DPM Reader.

Page 18 of 24

6.12 External Bulkhead connector Dust Caps

Dust caps have been provided for all external terminations to maintain the IP rating

for the enclosure and are tied to each respective bulkhead connector via a short cable

lead.

Once the installation has been completed and the DPM Reader switched on and

successfully booted up, please ensure all dust caps are replaced on unused bulkhead

termination ports.

6.13 DPM Reader System “OFF” Battery Charger “ON”

Should there be a requirement to charge the internal battery prior to AC mains start up,

then ensure both the AC Mains and DC Isolation switches are turned ”ON” and the

illuminated power switch is pressed off. The charging circuit is not a rapid charger and

will require at least two hours of charge to reach its nominal voltage level prior to

operation.

7 De-installation and Transportation of DPM

Reader

Should the DPM Reader need to be uninstalled and re-located or transported, power

down the illuminated power switch and then ensure both AC and DC isolation switches

are turned ”OFF”. Unplug all interface connectors. Unless the SIM card needs to be

removed, this can remain locked into the DPM Reader during relocation or

transportation.

The original packaging will accommodate leaving External air filter assembly fitted but

it can be removed if required by unscrewing it anti-clockwise. If removing the External

Filter Assembly, also remove the internal filter cartridge 100974 (not the external air

filter cartridge) and keep it in a safe clean place during transportation, ensuring that it is

re-installed when the DPM Reader is re-installed and the external air filter assembly re-

fitted.

8 User Maintenance

8.1 Regular Interval Servicing

The following components are to be replaced or maintained at regular intervals.

Frequency will depend on how harsh the environmental conditions into which the DPM

Page 19 of 24

Reader is installed. This is to ensure the DPM Reader achieves reliable

measurements and maximised operational lifetime.

Warning: There is no requirement to open the DPM Reader for user maintenance.

The unit must only be opened by a competent and suitably qualified technician.

8.2 Safety Control Level’s (SCLs)

Servicing, inspection, maintenance, diagnostic evaluation or repair of the DPM Reader

will likely take place under different power on conditions requiring attention to the

corresponding Safety Control Levels.

Safety Control Levels (SCL) defines the five safety conditions on the DPM Reader

depending on the states of mains isolation switch, battery isolation switch and power

button.

Familiarise yourself with the respective Safety Control Levels as detailed in table Table

1. The table illustrates the conditions of DPM Reader hazard areas based on the

respective switch status.

Safety

Control

Level

(SCL)

Mains

Power

Lead

plugged in

or out

DPM Reader Switch Status

DPM Reader Circuitry

Mains

Isolation

Switch

Battery

Isolation

Switch

Power

Button

Power

Modules

Battery

Charging

FAN

Measurement

Mains

Active

OFF

Mains

Active

Inactive

Active

OFF

Mains

Active

Inactive

OFF

Mains

Active

Inactive

OUT

OFF

Battery

Active

Inactive

Active

OUT

OFF

Battery

Active

Inactive

OUT

OFF

Inactive

5**

OUT

OFF

Inactive

** Note SCL Level 5 is ONLY to be used for Electrical Safety Testing per the Service Manual

TABLE 1-SAFETY CONTROL LEVELS (SCL) FOR DPM READERS

Caution: If there is a defect in any one of the switches, the actual SCL may be

higher than the described level.

A Safety Control Level (SCL) will be indicated for each module’s service instruction.

Page 20 of 24

Please Note SCL1, 2 and 3 requires the highest attention to safety.

SCL4 is the required safety level for close physical inspections, handling, module

disassembly and assembly.

SCL5 is to be used ONLY when a qualified and competent person is undertaking

electrical safety testing (Test and Tag) of the unit.

8.3 Servicing Interval Table

Items

Action

Harsh

environment

Minimum Period

months

Normal

environment

Minimum Period

months

6.1

External high dust

humidity filter

Draining filter housing

Cleaning metal fine

mesh filter

6.2

Internal clean air filter

cartridge

Replacement

6.3

Cyclone Filter

Cleaning

0.5

6.4

On/Off Button

Cleaning

6.5

*Measurement

chamber

Replacement

6.6

Visual inspection

6.7

Electrical test

Test and Tag mains

cable according to local

laws

As per local laws, or 12 monthly,

whichever is less

TABLE 2-REGULAR SERVICING RECOMMENDED SCHEDULE

* Only to be carried out by a suitably competent and qualified technician.

8.4 External high humidity and dust filter (05-0795) maintenance

The external high humidity and dust filter (05-0795) is to be drained at intervals as

specified in Table 2 - Regular Servicing Recommended Schedule and cleaned annually

as per the following instructions.

8.4.1 05-0795 External High Humidity Filter Removal

Warning: Set DPM Reader to Safety Control Level 4.

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