BOOKLET - Om80 Operator ManualV8-4

Sales Contacts Solartron International
SOLARTRON MOBREY
158 Edinburgh Avenue
ROXBORO GROUP
PLC
SOLARTRON MOBREY
GmbH
SOLARTRON MOBREY
LTD
OM80
Slough
Berkshire
Byron House
Cambridge Business
Postfach 13 01 40
D40551 Dusseldorf 13
Room 2016
Unicom International Tower
OBSCURATION
UK
SL1 4UE
Park
Cambridge
Deutschland
Tel: 00 492 119 98080
No. 547, Tian Mu Xi Road
Shanghai MONITOR
Tel: +44 (0)1753 756600 UK Fax: 00 492 117 489979 200070
Fax: +44(0)1753 823589 CB4 4WZ e-mail: mobreyD@aol.com China
Version SM-8.4 Plug-in units
e-mail: Tel: +44 (0)1223 424626 website: www.mobrey.de Tel: 00 86 21 63535652 From S/N 2000 November 2001
sales@solartron.com Fax: +44(0)1223 424656 Fax: 00 86 21 63535651
website: website: e-mail:
www.solartron.com www.roxboro.com mobreysh@online.sh.cn
INSTALLATION AND OPERATING INSTRUCTIONS
BESTOBELL SERVICE KDG INSTRUMENTS MOBREY Sp z o o MOBREY SA
CO. Crompton Way ul. Zupnicza 17 4 Rue Paul Painleve
LTD Crawley 03-821 Warszawa Z I Le Vert Galant
158 Edinburgh Avenue West Sussex Polska 95310 St Ouen L'Aumone
Slough UK Tel: 00 48 22871 7865 BP 675 - 95004
Berkshire RH10 9QR Fax: 00 48 22871 7869 Cergy-Pontoise Cedex
UK Tel: +44 (0)1293 866000 website: France
SL1 4UE Fax: +44(0)1293 530849 www.mobrey.com.pl Tel: 00 331 3430 2830
Tel: +44 (0)1753 756600 e-mail: Fax: 00 331 3430 2831
e-mail: sales@solartron.com
sales@solartron.com
SOLARTRON MOBREY SOLARTRON
AB MOBREY
Box 5056 SA-NV
S-121 16 Johanneshov Nestor Martin Street 315
Stockholm B-1082 Brussels
Sverige Belgium
Tel: 00 468 725 0100 Tel: 00 32 2465 3879
Fax: 00 468 394 752 Fax: 00 32 2465 0481
e-mail: e-mail:
mobrey@mobrey.se blsales@mobrey.com
website: www.mobrey.se
For further information contact

Meggit Mobrey Ltd
190-196 Bath Road
Slough Berks
England SL1 4DN
Tel: 01753 534 646
Fax: 01753 823 589
e-mail: sales@Mobrey.co.uk
http://www.mobrey.co.uk
Service http://www.om80.com
22-Oct-02 Om80 Operator ManualV8-4.doc Page 24 of 24 22-Oct-02 Om80 Operator ManualV8-4.doc Page 1 of 24
Agents Australia
Manufacture and Distribution
NSW Bathurst VIC/TAS QLD
International Sales Technical Support
Westech Metaval Fluid Control Sales
Meggit Mobrey Ltd BHO Control Engineering Pty Ltd
11 Bradwarine Rd. 17 Kelvin Rd 160 Fison West Av. Unit 3
190-196 Bath Road 11 Murdoch St. Bathurst NSW 2795 Bayswater VIC 3153 Eagle Farm QLD 4009
Slough Berks Ermington NSW 2115
England SL1 4DN Po Box 104 Ermington 1700 Po Box 316 Bathurst Po Box 1093 Croydon Po Box 1310
NSW 2795 VIC 3136 Eagle farm Business centre
Tel: 01753 534 646 Tel 02 9638-3833 QLD 4009
Fax: 01753 823 589 Fax 02 9684-4245 Tel 02 6332-9966 Tel 03 9761-4000 Tel. 07 3268-6866
Fax 02 6332-9967 Fax 03 9761-4006 Fax 07 3268-5466
E-mail: E-Mail
sales@Mobrey.co.uk theobee@matra.com.au E-Mail E-Mail E-Mail
westech@lisp.com.au andrew@metaval.com.au sales@fluidcontrol.com.au
Website Website
http://www.mobrey.co.uk http://www.OM80.com Website Website Website
http://www.mataval.co.au http://www.fluidcontrol.com.au
John Davison Theo Beemsterboer Mick Flanagan
Mob 0418-299-212 Andrew Garland Martin Phelan - Des Lowrie
Distribution Australia Distribution Singapore SA/NT WA
Measurement Plus Pty Ltd Controls Plus Pte Ltd Perryco Pipeline actuation and
control
Po Box 4110 30 Toh Guan Road, 563 Magill Rd.
Balwyn East VIC 3103 #07-04B ODC Districentre Magill SA 5072 40 Bowen St.
Singapore 608840
OConner WA 6163
Po Box 113 Magill
Tel 03 989 73908 Tel : (065) 6425 5575 SA 5072 Po Box 1152 Bibra
Fax 03 989 73909 Fax: (065) 6560 9665
Lake WA 6163
Tel 08 8332-2556
E-Mail: E-Mail: Fax 08 8364-0192 Tel 08 9314-1827
s.smith@measurement-plus.com.au amyaw@controls-plus.com.sg
Fax 08 9314-1837
E-Mail perryco.senet.com.au E-Mail sales@pipact.com.au

Simon Smith Amy Aw
Mob 0410-636-171 Website Website
http://www.perryco.com.au http://www.pipact.com.au
John Tindale
Dave Perry Chriss Duffy
INDEX
c. Vibration of the optics can damage the lamp filament, sagging and blackening and a short lamp life
result, a rising reading during the period would be evident. Mounting the optics on their own stand and
coupling them with bellows or rubber sleeves to the stack usually will fix this problem. Refer to 6.1a. Specifications 4
Control Unit 4
Projection/Receiver Units
d. Mechanical Stability is of prime importance. Verify all components such as lenses, lamp holders, Safety Information
globes etc. are properly mounted and the correct O rings are fitted, gently tapping of the housing should Operating principle 5
not cause a shift in operating conditions. Installation 6
Preliminary Instructions 6
e. Contamination of the lens is compensated up to three percent per day. If dust or soot in excess of SECTION ONE
this gets deposited, an increasing obscuration will be observed. With negative pressure stacks, a gap on Installation - Projector & Receiver Units 7
the mounting flange can be the solution, drawing in outside air. Otherwise an air purge system might be 1.0 General 7
needed, refer to 1.8. Boiler installations can deposit considerable soot during blow down, a shutter can Typical Installation 7
solve the problem. 1.1 Location 7
1.2 Temperature 7
f. Dew on the lenses can be a problem, normally evident by a rapid rise in readings up to fifty percent 1.3 Accessibility 8
1.4 Scanning Distance 8
when the lenses fog up, the receiver is the most likely culprit, the transmitter is heated somewhat by the 1.5 Stratification 8
lamp. Normally this is observed on cold days in the early morning when the optics drop below the dew 1.6 Sunlight 8
point of the stack air, or when warm, moist air is exhausted up the stack. Either air purging with dry air or 1.7 Mounting Optical Units 9
heating the optics above the dew point using a heat trace cable will solve this problem. The trace cable 1.8 Negative Pressure Applications 9
should not increase the temperature of the optics above 60C. Normally 40C would be sufficient. i. Indoor Locations 9
ii. Outdoor Locations 10
1.9 Positive Pressure Applications 10
g. Thermal effects from direct exposure to the sun or high stack temperatures will create drift, a
i. Air Purging 10
sunshade or isolating the optics from hot stacks will solve this. The receiver temperature co-efficient is
about 0.2% per degree, this is adequate to cope with normal ambient deviations but not the extreme SECTION TWO
swings experienced with direct sun light exposure or high temperature stacks. Electrical Connections
2.0 Optical Units 11
h. Light ingress at the stack opening is another common problem, usually caused when the optics are 2.1 Mains Connection 11
mounted too close to the stack exit or sunlight shines inside a reflective stack. This should be minimised 2.2 Alarm Relays 11
by correctly mounting the optics away from the stack exit, a matt black finish in the stack and mounting 2.3 Analogue Output 11
2.4 Wiring Diagram 12
tubes, etc, will help. Within limits the OM80 software automatically compensates for variations in ambient
light conditions in the stack, however prevention by relocating the optics is better then cure. SECTION THREE
Internal Presets
i. Incinerators pose their own range of problems. Occasional flames or temperatures so high there is 3.0 Conversion Dust/ Combustion Mode 12
an internal glow in the stack. If the flames are of short duration the OM80 can compensate for these 3.1 Setting analogue Output Span 13
variations. The unit cannot function where the flames are continuous or a permanent glow is emitted by 3.2 Printed Circuit Board Diagram 14
the exhaust particles. If the flue emits a low level visible light (red hot) a possible solution is to calibrate
SECTION FOUR
the unit after operating temperatures has been reached. Generally speaking this application is not
Keyboard Operation & Programming
recommended. 4.0 Function Entry Procedure 14
4.1 Parameter List 15
4.2 Operator Accessible Functions 15
4.3 Password Accessible Functions 15
4.4 Messages during operation 16
SECTION FIVE
Commissioning & Operating Procedures
5.0 Raw Stack Value 16
5.1 Calibration Procedure 16
5.2 Alarm Set Points 16
5.3 Analogue Output 18
5.4 Chart Recorder Check 18
5.5 Daily Optical System Check 18
5.6 Auto Calibration Following Lens Cleaning 19
SECTION SIX
Troubleshooting
6.0 Keypad/Display 19
6.1 Optical Units 19
6.2 Output Relays 19
6.3 Electrical Noise 20
6.4 Service Notes 20
SPECIFICATIONS c. Input Stability
Control Units A ready way to check the input is input is by means of injecting 50uA DC (negative input) and observing
the RSV is stable, in range and proportional to the input voltage.
Power requirements: 100-240 V AC, 50Hz The RSV is observable after invoking Mode 9 and is adjustable by mains of the gain potentiometer at
Obscuration Range: Display 0% to 100% the rear of the unit.
Analogue Output: 4 to 20mA for 0% to 50%/ or 0 to 100% obscuration, selectable via DIP switch
Alarms: Two SPCO, Uncommitted, each rated at 2A, 250 Vac The RSV is observable after invoking Mode 9 and is normally in the range of 4000-5000 with a typical
Alarm Mute: 2 minute reset value of 4500 whit the lamp switched off or the input disconnected.
Keyboard: Touch Membrane With an in put current of 50uA the RSV is adjustable to 8000 or so, typically it is set for 7500, this gives
Display: 12mm LED the unit some margin if extraneous light enters the optics, of course at no time should the value exceed
Memory: 14 days the saturation point during normal operation.
Calibration: Automatic zero and span
Zero Reset: Software provides up to 3% per day self zero negative ramp to offset progressive lens Again these readings should be stable within say ten points or so, the precise value is not important, +/-
contamination 100 is fine
Security: Password protected programmable entries
Optical Check: Not password protected The lower reading is dependent on the sensor and the gain selected and can vary considerably between
Operator can display stack quality figures installations, again, the main consideration is stability. If there is doubt a test kit can be used to allow
Temperature Limits: -10C to 55C ambient bench testing and calibration without the optics.
Panel Cut-Out
Dimensions: H80mm x W180mm x D180mm
d. Optics and their connection are the most common source of problems.
Projector/Receiver Units
Measuring the photocell current and the lamp voltage at the stack can solve virtually all stack
Projector: Type I 1537 problems.
Lamp: 2.8W, 24Vdc Tungsten filament When trouble is evident observe the cause of deviation from a steady reading, inspecting the
Note; filament shape and position is important chart recorder for time dependent trends can be helpful.
Receiver: Type I 1538
Cell: Silicon photovoltaic A current meter across the solar cell (disconnect the cable) is an easy way to observe the received signal
Scanning Distance: 300 to 3000mm (standard unit) at the stack.
Flanges: 80mm NPS AS2129, Table E
Mounting Tube: Optional extra The photocell should produce a minimum of 50uA; depending on the stack it can go as high as several
Air Purge: 3/8 inch BSP connection milly Amps. When too high, the RSV reading cannot be reduced to 7500, a ground glass lens must be
Degree of Protection: IP54 fitted to the transmitter to reduce the lamp brightness.
Max. Temperature: 70C The lamp voltage can also be reduced a volt or so, (not recommended), see section 6.1 and PCB
Weight: Projector 2kg. Receiver 2kg. OM80 1.5kg. drawings.
Things to check
a. Cabling must be instrument grade shielded cable and earthed only at the instrument, not at the stack.
Failure to do so can induce stray voltages and will increase the likelihood of damage from lightning.
Cabling should be run well away from mains wiring to avoid interference. The wire gauge should be
adequate to minimise the voltage drop to preferably less then 0.1 V. (this works out to approximately 1
Ohm loop resistance). Lamps are 24V 2.8 Watts. Do not use replacement lamps of different mechanical
design or rating, filament shape and position is especially important. The original equipment lamps are a
special automotive short filament tungsten design.
b. Alignment should be correct and not vary. A common problem is misalignment of the optics, observe
the beam current (or RSV in Mode 9) and see if by properly aligning the optics a higher reading can be
obtained. Applying pressure to the optics will show any inadequate mounting. If the mounts are flexing
this will show as a deviation in the received current. Refer also to 6.4a. Other alignment problems can be
due to inadequate mounting, I.e. mounting on a flat steel surface that buckles with temperature or duct
pressure can cause a substantial deviation in the received current.
Important Safety Information
6.3 Electrical Noise
Electrical noise problems can be observed by invoking MODE 11 (lamp off) and then MODE 9, and note Manufacturer: BHO Control Engineering Pty/Ltd
100% RSV value. Observe reading to be stable and not unduly influenced by starting and stopping of Po Box 104, Ermington NSW 2115, Australia
electrical apparatus in the vicinity (such as fans etc.).
European Solartron Mobrey Ltd
Invoke MODE 10 (lamp on) and them MODE 9, note 0% RSV value. Observe reading to be stable and Distributor: 190-196 Bath Rd, Slough
not unduly affected by pressure applied to the optics, vibration at the optics or electrical apparatus
starting or stopping. Berkshire SL 1 4DN England
Refer Section 5.1 for key pad sequence. Supply Voltage: 100-240V AC +/- 10%
Power Rating: 45VA
The reading should be stable in the short term say within +/- 4 digits in a 1 minute period under clear
stack conditions.
Relays: Maximum rating 240V 2A
Refer Section 2i, for correct wiring requirements. Failure to observe these may result in earth leakage
problems. Environmental: The control unit is designed to be safe under the following conditions
-Indoor use or weatherproof enclosure
-Altitude up to 2000 meters
6.4 Service Notes On Unstable Readings, - drift -Temperature 10% to 55%
-Relative humidity 80% up to 31 C
The service manual explains the general operation and troubleshooting and should be followed first.
-Installation category II
This guide is intended where the basic unit appears functional but drift occurs after commissioning. This
is generally due to errors introduced due to faulty cabling or installation of the optics. -Pollution degree 2 in accordance with
It must be noted a few percent variation when temperature or other conditions vary is not uncommon. IEC 664
a. Possible causes of variation in received signal are: Installation: Refer to this manual
Equipment housing must be Earthed
i, Thermal effects in the optics, i.e. make sure the optics, especially the receiver are not exposed to The control unit must be protected by a 2A
excessive temperatures swings, 70C absolute maximum.
fuse in the mains supply and fitted with a suitable
ii, Alignment variations in the optics due to warping of the stack or mounting assembly. On lightweight switch or disconnecting device which should be
ductwork it will be necessary to brace the mounting tubes using an angle iron framework. located near the equipment.
iii, Verify the recorder does not introduce extraneous grounds at the shield or at the signal wiring. The Explanation Protective Earth
recorder input must be floating.
of symbols
b. Lamp Voltage
Cleaning The control unit facia may be cleaned by gently wiping
Make sure the lamp voltage is correct and can be switched on and off by means of invoking mode 10 with a damp cloth
and 11.
Maintenance The control unit requires no maintenance.
The units are shipped with the lamp voltage set for 23.5V, but it is adjustable internally (potentiometer on
PCB) to accommodate other operating conditions, the main concern is it should be stable at the stack. It
There are no user serviceable parts inside.
is not recommended to reduce the voltage too much. The light will get progressively less white and there Disconnect power supply before removing cover.
will be an extra thermal load on the regulators causing variation. Drift at the stack should be less then
0.1V after warm up. Refer also to to section 6.1. Note If the equipment is not used in a manner specified by the manufacturer
the protection provided by the equipment may be impaired.
It is recommended to fit the ground glass lens if the photocell current is too high causing difficulties in
adjusting the RSV below around 7,800, (The converter is in saturation, some models have inbuilt
detection and report the error as Hi on the display). Scanning distances less then 1.2m generally require
fitting the ground glass lens.
5.6 Auto Calibration Following Lens Cleaning
Operating principle
Following lens cleaning by the operator the electronics will automatically re-set zero to the new clean
The Om80 comprises two optical units, a projector (light source) and receiver (photo voltaic lens RSV value..
cell), which are mounted on the boiler stack, or exhaust duct. The optical units are connected
a. 0.0% will be displayed during zero re-set calibration period, which may take several minutes or longer
by means of two twin-shielded cables to the control unit, normally located in the boiler house depending on the amount of adjustment required.
or plant room.
SECTION SIX
The control unit measures percentage obscuration of the light source caused by soot or dust
particles passing through the beam, and converts this to a digital display. TROUBLESHOOTING
An analogue output for a chart recorder or other monitoring equipment is also provided, plus
6.0 Keypad/Display Failure
two independently set alarm relays.
If the unit has the correct Mains voltage available, the keypad should be active and the display functional.
The OM80 continuously monitors the measured and ambient light conditions in the stack and If the keyboards is not, or partially functional, check the internal ribbon cable for proper connection.
automatically tunes the zero and span values to provide stable readings under widely varying
conditions. Due to security aspects, conditions can arise when access cannot be gained to the unit, either because
the current password has been lost or the standby battery has failed etc.
The control unit will automatically recalibrate the zero value when the optics are cleaned, and
recalibrates the span when extraneous light enters the stack. Normal functions may be re-instated by disconnecting the power supply for 1 minute. Reconnect power
This can be caused by sunlight or flames from an incinerator which may be burning volatiles. supply and if normal operation is not resumed please contact your distributer
The light source is switched of at regular intervals to monitor the ambient light condition.
6.1 Optical Units
The keypad is password protected and may be used to auto calibrate the unit or change
other parameters. A Test button is provided to verify and monitor the condition of the optical i. Transmitter
units. Full details are explained in this manual. Except during calibration, the lamp should be illuminated and have 23.5 V DC available at all times, if the
Note, for recalculation of obscuration to other measurements such as Ringelman, voltage at the lamp deviates more than 0.2 V DC the internal potentiometer may be used to adjust the
Transmittance, Optical density etc. voltage level, do not exceed 24 V DC (measured at the lamp terminals). See P.C.B.. diagram for location
Additional information is available from www.OM80.com - Section 3.2.
INSTALLATION ii. Receiver
The measured signal can be checked by means of inserting a current meter in series with one lead of the
Preliminary Instructions
receiver, for normal stacks a reading of not less than 50 micro-amps should be observed. If this reading
is less, disconnect the wires and observe the resistance across them, it should exhibit a typical diode
The following points should be carefully observed:
behaviour, i.e. infinite readings one way and say 40 Ohms the other direction (varies with meter used,
use diode setting on digital meters).
1. Do not ground cable shields at the optics.
2. Keep shielded cables to the optical system away from 240/415-Volt cables - minimum clearance
300mm. If readings in the kOhms range are obtained, verify the series resistor in the receiver has been shorted. If
the received current is too low, excessive gain would have to be applied, this results in difficult
3. Optical units must be rigidly mounted and properly aligned. adjustments and an increase in drift and noise problems.
4. Avoid temperature swings and extremes at the transmitter, receiver and cable junctions i.e. Check adjustment and alignment of the optics.
direct sunlight, hot stack etc. Max temperature 70C.
6.2 Output Relays
5. Prevent external light sources affecting the optics i.e. install away from duct or flue exit.
The relay circuits can be activated by depressing the relevant alarm button for more than 3 seconds.
Depressing the ALARM 1 or ALARM 2 key will display the selected set point, holding key for longer than 3
seconds activates the respective alarm relay. SECTION ONE
5.3 Analogue Output INSTALLATION - PROJECTOR AND RECEIVER UNITS
The 4 to 20mA output corresponds to an obscuration span of 0 to 50%, or 0 to 100% as selected. (See
1.0 General
Section 3.1).
To avoid possible errors in obstruction readings due to infiltration of air the optical units should be located
5.4 Chart Recorder Check away from the flame area and downstream of any flue gas sampling points. The optical beam should be
located where it will best monitor particle emissions and not near bends or dampers which may cause
Zero, mid and full scale values (4, 12, 20mA) can be generated. stratification.
Use the following parameter numbers as required. In instances where optical units are mounted on the suction side of the ID fan and the fire bed is
periodically banked, it may be desirable to provide shutters to prevent sooting-up when the dampers are
Parameter Function closed. This method may also be employed to protect the lenses during soot or dust blowing.
5 :- 4mA zero check
6 :- 12mA mid-scale check Where necessary, the optical units may be located outdoors and are weatherproof (IP54) without
7 :- 20mA full-scale check additional protection. The associated wiring must be suitably weatherproof.
8 :- Slow ramp 0 to 24mA (to check recorder pen moves freely)
(An adjustment is provided inside the unit for the 4mA setting, provided the external loop resistance is within TYPICAL INSTALLATION
specification the other values should be correct.)
5.5 Daily Optical System Check

It is recommended that a daily optical system test is carried out by pressing the TEST keypad. This will T r a n s m itte r R
display RSV SPAN which is the difference between zero and 100% span RSV values and is used to
indicate lens and lamp condition. Under ideal conditions the RSV SPAN is approximately 2800 to 3600.
When this figure falls to a low value, say 2000 it indicates the lenses require cleaning or lamp needs to
be replaced. D u s t B a g H o u s e o r
S o lid F u e l/ O il F ir e d B o ile r
RSV span values between 2000 and 3600 indicated that sufficient signal is being received to carry out a
successful automatic ZERO and SPAN calibration without cleaning the lenses.
1.1 Location
For example, an operator may, at the start of a shift, observe an obscuration value of, say 7% with the
plant shut down. This would indicate lens contamination. On depressing keypad TEST this may indicate These units must be rigidly mounted in the horizontal plane on opposite sides of the stack or duct so that
a RSV SPAN of, say 2856, thus indicating that sufficient signal exists to proceed with an automatic the projector light beam is at right angles to the flow of flue gases and gives unrestricted illumination of
ZERO and SPAN calibration without cleaning lenses. the receiver photocell. The following considerations should be taken into account when choosing a
suitable location.
This procedure may be repeated daily until RSV SPAN approaches 2000 indicating that the optical
system needs checking and cleaning. 1.2 Temperature
A reading of 1000 is an absolute minimum and below this the unit locks out into fault condition and It is preferable that the units are installed where the ambient temperature and ambient temperature
indicates LITE and calibration is not possible. Lens or lamp require attention. Refer to Section 5.1 for variation is at a minimum. When correctly installed on mounting tubes conducted heat is not usually a
recalibration sequence. problem. Radiated heat, which has the greater effect on the units, can be effectively reduced by suitable
lagging of adjacent hot surfaces. Air purging provides normally sufficient cooling effect. The temperature
of the projector/receiver units should not exceed 70C, where the temperature of the projector/receiver
units could exceed 70C please consult your distributor.
Select Mode:
1.3 Accessibility
Optical units must be located such that they are readily accessible for lens cleaning, routine maintenance
and servicing.
Whilst the optical units will function correctly at temperatures up to 70C, locations of high ambient
temperature should be avoided as far as possible so that routine maintenance and service can be carried The unit now displays the raw stack value (RSV)
out whilst the plant is in operation.
iii. Adjust gain via multi-turn potentiometer at rear of the control unit to trim this value to read 7500, +/- 100
1.4 Scanning Distance (see Section 3.2) for location on pcb. (Turning clockwise increases the reading) The gain of the instrument
is now set for the scanning distance of the optical units.
It is recommended that the scanning distance be kept within the limits 300mm to 3000mm. Where the Note this assumes a normal input current of 40uA minimum.
distance between the duct walls is greater the mounting tubes may be extended into the duct to reduce
the scanning distance, see Section 1.7. RSV is a function of lamp brightness, clean lens, and correct alignment. Whilst in MODE 9 the installer
should check for optimum alignment of optical system. The higher the number the better the alignment.
Scanning distances less than 300mm should be avoided if possible. For scanning distances outside the
recommended range, please consult Beacon Engineering Products. As a general guide, for scanning distances less than 2 metres, the ZERO RSV should be greater than
7500 on initial start up, the factory set-up is for inputs of 50uA. If less, carefully check optical system.
1.5 Stratification
If the optical system is installed correctly (i.e. alignment and properly screened cables) the ZERO RSV
To ensure that the smoke or dust measured by the instrument is representative of that emitted, the will be easily set to approximately 7500. However, if readings are unstable, drift, or the adjustment difficult
influence of dampers, bends, tees, obstructions and draught balance doors should be considered when or unobtainable refer to Sections 6.2 ii and 6.5
selecting a suitable position. Location of the units close to bends in the flue should also be avoided as
the momentum of the flue gases may deposit dust on the lenses. iv. Auto Zero and Span Calibration
1.6 Sunlight Keypad Sequence continues as follows:
The optical units should not be installed at the flue opening to atmosphere as ambient light may affect
the stability of readings.
Within limits the software will provide automatic compensation for this problem, however excessive light
ingress will necessitate special calibration points.
(The unit will auto calibrate zero and span for approximately 30 seconds)
The display shows in sequence the following;
CAL1 = 100% span

(Brief display of RSV 4000 to 5000)
CAL2 = Zero
(Brief display of RSV 7400 to 7600 clean lens condition)
The unit will automatically return to RUN mode and displays a reading close to zero obscuration -
Calibration procedure is now complete.
Verify the RSV SPAN value is in the range 2000 to 3600 by depressing TEST keypad.
5.2 Alarm Set Points

i. Check alarm set points are set correctly for application by depressing the respective buttons.
Alarm 1 Alarm 2
Combustion 20% 25%
Dust 5% 10%
If incorrect for your application refer to Section 3 for appropriate conversion. (ie combustion to
dust or dust to combustion).
Alarm set points may be changed (not recommended), refer to Section 4.
ii. Alarm Check
Calibration should only be carried out under clear stack conditions.
1.7 Mounting Optical Units
The diagram below indicates the method of mounting to optical units on a steel duct or chimney.
Depressing RUN returns the unit to the normal operating mode. Mounting tubes are normally supplied and fitted by the steel fabricator and must always be installed in
the horizontal plane.
4.4 Messages during operation The mounting tubes should be fabricated from 80mm schedule 40 pipe (or equivalent) and BS10
schedule E flange as illustrated below. The minimum overall length should be 250mm to avoid sooting
Periodically the unit will check the calibration points, older units showed various messages on the display, of lens and B dimensions approximately 50mm provided that at least 250mm active scanning distance
preventing reading the current value. is available between the tubes.
Later units show C followed by the reading.
In addition when adjustments are needed the unit briefly can show P as well. The tube ends should be tapered approximately 30 as shown to minimise lens sooting.
SECTION FIVE Note: Arrow indicates direction of Gas Flow in relation to tube end cut-off.
COMMISSIONING AND OPERATING PROCEDURES
5.0 Raw Stack Value (RSV)

The OM80 will automatically calibrate zero and span from RSV values obtained with the transmitter lamp
ON (for zero) and OFF (for 100% obscuration)
i. 100% Obscuration Span

Transmitter lamp OFF RSV approximately: 4000-5000. The RSV at 100% obscuration is not adjustable
and is for reference only.
ii. 0% Obscuration
Transmitter lamp ON RSV approximately: 7400-7600 under clean lens conditions, adjustable by means of
Gain Potentiometer at rear of unit, see next section..
iii. RSV Span

RSV Span is the difference between 0% RSV and 100% RSV, under clean lens conditions typically 2800
to 3600, it is shown by means of the TEST button and gives an indication of the lens condition.
1.8 Negative Pressure Applications
5.1 Calibration Procedure
Wherever possible the optical units should be installed at a negative draught location avoiding high gas
i. After power up, the unit displays a software reference (P3.0, P4.0 etc), and displays COLD for some turbulence due to fans, bends and dampers. Such a location will minimise lens sooting by allowing a
time to enable the unit to stabilise before calibration, (For service this can be stopped by pressing CAL or stream of clean external air to be drawn into the mounting tubes via a small gap between flanges as
RUN key) followed by a random uncalibrated obscuration values. described below.
ii. It is necessary to adjust the control units Gain to suit the scanning distance and alignment of the i. Indoor Locations
optical units. A multi-turn potentiometer at the rear of the unit is used to set the gain so that the RSV reads Where the pressure inside the stack or duct is less than atmospheric, the projector and receiver units
approximately 7,500. should be bolted to the mounting tubes using washers to provide a 3mm spacing between the flanges.
Atmospheric air will be drawn through the gap and into the units, so keeping the lenses free from soot or
dust. The 3/8 inch BSP tapping should be plugged.
Key Sequence: Password entry
If the changed value is correct, depressing ENTER accepts the new value, depressing CLEAR reinstates
ii. Outdoor Locations the old value.
On externally mounted optical units care should be taken to prevent rain entering the gap between flanges 4.1 Parameter List
as this may affect obscuration readings. The upper side of the flange gap should be sealed by fitting
several half gaskets between the two upper flange bolts. Normal spacer washers should be fitted to the Parameter Function
lower bolts. In view of the reduced natural draught induction area the gap should be increased to 5 :- set output to 4mA
approximately 5mm. 6 :- set output to 12mA
7 :- set output to 20mA
8 :- ramp output from 0 to 24mA
9 :- shows current RSV
10 :- switch lamp on
11 :- switch lamp off
12 :- change alarm 1 set point
13 :- change alarm 2 set point
14 :- change password
19 :- full reinitialisation of CAL, default password and set points
1.9 Positive Pressure Applications 4.2 Operator Accessible Functions

Where the pressure inside the stack or duct is greater than the atmospheric, the projector and receiver
units should be bolted to the mounting tubes using a gasket to provide an airtight seal between the Depressing the Alarm 1 key shows value of the setpoint and if held for more than
flanges. 3 seconds activates relay 1.
On oil fired boilers a pressure wave may be caused when the burner ignites disturbing soot
accumulations and depositing them on the lenses. Therefore, the units should be located as far as
possible from the actual flue gas outlet of the boiler. Injecting clean air is not always effective as the Same as above for setpoint 2 and relay 2.
momentary pressure can be severe. Accordingly, it is important to observe this precaution even when
injected clean air is used during normal running conditions.
Air Purging
Depressing the Mute key deactivates relays for 2 minutes to enable corrective
To minimise sooting-up of the lenses during normal operation, air pressurised above the stack pressure action to be taken, mute can be cancelled by operating ALARM 1
should be fed via flexible tubing into the 3/8 inch BSP tapping provided on each unit. The air supply key.
should be switched on before the boiler is fired and should not be switched off until after the firing
sequence has shut down and the purge cycle is complete.
Air supply may be a compressed air line or from a small blower. Purge air pressure must exceed duct or Operation of this key displays the RSV Span and indicates the condition of the
flue pressure. optical units. (See 5.0 for details).
(See Daily Optical System Check - Section 5.5)
4.3 Password Accessible Functions
Depressing the Mode key displays for 1 minute the word PIN and the password
(2115) can be entered.
When the password is entered successfully the display shows SET, and the unit is in the
Entry mode. The CAL and RUN keys as well as the numerical keypad become active.
See parameter list, Section 4.1
Depressing CAL recalibrates the OM-80 without affecting any other parameters
(mode 19 does a complete initialisation ie. calibration and return to default
setpoints and password).
3.2 Printed Circuit Board Diagram SECTION TWO
ELECTRICAL CONNECTIONS
2.0 Optical Units
Use instrumentation grade shielded cables for connection to the projector, receiver and control unit. Run
the cables separately from any mains cable (300mm minimum separation). Cable shields to be
grounded only at control unit.
Maximum cable length is governed by the total loop resistance of the core and should not exceed the
following limits.
Projector: 5 Ohms
Receiver: 30 Ohms
Analogue Output: Total loop resistance, including recorder, should be less than 350 Ohms. (OM80
output is grounded and therefore chart recorder inputs should be floating).
2.1 Mains Connection
The unit has a switchmode power supply (SMPSU) and will operate on any voltage between 100-240V
47-63Hz, The unit will also accept 120-265 V DC although this is not marked on the rear of the
enclosure. All OM80 EC marked units have this capability. For optimum performance the mains supply to
the OM80 should never be interrupted. However under normal conditions the internal values will be
maintained for a minimum of 28 days.
2.2 Alarm Relays
Alarm relays are rated at 2 Amps 250 Vac non-inductive load and provide non committed change over
contacts for external circuits. These circuits may be used for alarm or control function and 2 A fuses must
be provided in the customers switchboard.
Please observe safety information provided in this manual.
2.3 Analogue Output
The 4 to 20mA output corresponds to an obscuration span of 0 to 50% or 0 to 100% obscuration as

selected on DIP switch. See Section 3.1. and 5.4.
SECTION FOUR
KEYBOARD OPERATION & PROGRAMMING
4.0 Function Entry Procedure

1. Enter password (key sequence):
2. Enter desired function number (see parameter list) and depress ENTER, the unit normally responds
with a message describing the requested function.
3. Functions such as lamp on etc are active during the message display.
Functions allowing change of parameters display existing values after depressing ENTER and allow
changes by means of the numeric keyboard.
a. Wiring Diagram
Password entry
At this point the display should show Set or Pass, continue with:
At this point the display shows Go, depressing Enter again will re-initialise the unit, any other key
return to set-up mode.
Verify the alarm setpoints by returning to operational mode (press RUN or CALL) and operating the
ALARM 1 and ALARM 2 keys.
3.1 Setting Analogue Output Span

The analogue output is factory preset at 0 - 50% obscuration corresponding to 4-20mA. This provides
better resolution for chart recorder as generally readings are close to zero.
However, 0-100% span may be invoked by moving switch 2 of DIP switch to ON as shown.
SECTION THREE
INTERNAL PRESETS
3.0 Conversion Dust/Combustion Mode
The OM80 is pre-programmed with two operating modes, a dust mode for monitoring emissions from air Invoke keypad sequence in 3.0 to initialise new value.
filtration plant etc, and a combustion mode for monitoring smoke emission. Alarm relay default values are
factory preset as follows: Note: DIP switches 3 & 4 must be left in the OFF position, these serve other functions.
Combustion: Setpoints 20 & 25% 5 and 10 second delay

Dust: Setpoints 5 & 10% 30 and 60 second delay
Setpoint values may be changed to suit local conditions, Ref. Section 4.
Note: A 30 and 60 second delay is provided in the DUST mode to allow for dust to clear the stack
during and after purge cycles.
Switch 1 on the DIP switch adjacent the display ribbon cable should be preset as shown:
Note: DIP switches 2, 3 and 4 must be left in the OFF position, these serve other functions.
Following operation of the DIP switch invoke mode 19 to initialise newly selected operational mode.
Key Sequence

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Sales Contacts Solartron International

For further information contact

E-Mail perryco.senet.com.au E-Mail sales@pipact.com.au

INSTALLATION ii. Receiver

5.5 Daily Optical System Check

1.6 Sunlight Keypad Sequence continues as follows:

The display shows in sequence the following;

CAL1 = 100% span

5.2 Alarm Set Points

Alarm set points may be changed (not recommended), refer to Section 4.

ii. Alarm Check

COMMISSIONING AND OPERATING PROCEDURES

5.0 Raw Stack Value (RSV)

i. 100% Obscuration Span

iii. RSV Span

1.9 Positive Pressure Applications 4.2 Operator Accessible Functions

4.3 Password Accessible Functions

2.1 Mains Connection

2.2 Alarm Relays

2.3 Analogue Output

The 4 to 20mA output corresponds to an obscuration span of 0 to 50% or 0 to 100% obscuration as

KEYBOARD OPERATION & PROGRAMMING

4.0 Function Entry Procedure

3.1 Setting Analogue Output Span

Combustion: Setpoints 20 & 25% 5 and 10 second delay

Setpoint values may be changed to suit local conditions, Ref. Section 4.

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