Operation and Maintenance Manual

Transcription

1 Operation and Maintenance Manual Model 4500 MkII+ Dust /Opacity Monitor Publication Nº Language English Issue 7 September 2012 Combustion & Environmental Monitoring

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3 IMPORTANT INFORMATION - PLEASE READ Important Health and Safety Information Equipment Operation Use of this instrument in a manner not specified by Land Instruments International may be hazardous. Electrical Power Supply Before working on the electrical connections all of the electrical power lines to the equipment must be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these operating instructions. If in doubt contact Land Instruments International. Face and Eye Protection Suitable face and eye protection must be worn when working on hot vessels and ducts! Special safety measures must be taken when working on a high-pressure duct. Protective Clothing Protective clothing must always be worn when working in the vicinity of hot vessels or ducts. Storage The instrument should be stored in its packaging, in a dry sheltered area. Office Locations UK - Dronfield Tel: +44 (0) land.combustion@ametek.co.uk Web: USA - Pittsburgh AMETEK Land, Inc. Tel: combsales@ametek.com Web: For further details on all LAND/ Ametek offices, distributors and representatives, please visit our websites. Unpacking Check all packages for external signs of damage. Check the contents against the packing note. Return of Damaged Goods IMPORTANT If any item has been damaged in transit, this should be reported to the carrier and to the supplier immediately. Damage caused in transit is the responsibility of the carrier not the supplier. DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save the packing with the damaged article for inspection by the carrier. Return of Goods for Repair If you need to return goods for repair please contact our Customer Service Department. They will be able to advise you on the correct returns procedure. Any item returned to Land Instruments International should be adequately packaged to prevent damage during transit. You must include a written report of the problem together with your own name and contact information, address, telephone number, address etc. Return of Goods for Repair Form is available for download from our websites. Lifting Instructions Where items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the Technical Specification for weights. All lifting should be done as stated in local regulations. Design and Manufacturing Standards The Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for the design, manufacture and on-site servicing of combustion, environmental monitoring and non-contact temperature measuring instrumentation. Signs and Symbols Used on Equipment and Documentation Caution, risk of electric shock. This item or material can be recycled. Caution, attention to possibility of risk of damage to the product, process or surroundings. Refer to instruction manual. Approvals apply in the USA This instrument complies with current European directives relating to Electromagnetic Compatibility 89/336/EEC and Low Voltage Directive 73/23/EEC. Operation of radio transmitters, telephones or other electrical/electronic devices in close proximity to the equipment while the enclosure doors of the instrument or its peripherals are open, may cause interference and possible failure where the radiated emissions exceed the EMC directive. The protection provided by both CE and IP classifications to this product may be invalidated if alterations or additions are made to the structural, electrical, mechanical or pneumatic parts of this system. Such changes may also invalidate the standard terms of warranty. Caution, hot surface. This item or material can be recycled. This item or material must be disposed of in accordance with the Waste Electrical and Electronic Equipment directive as applied by local regulations. Protective Conductor Terminal. Observe precautions for handling electrostatic discharge sensitive devices. Dimensions Unless otherwise stated, all measurements are given in millimetres and inches. Copyright This manual is provided as an aid to owners of Land Instruments International s products and contains information proprietary to Land Instruments International. This manual may not, in whole or part, be copied, or reproduced without the expressed written consent of Land Instruments International Ltd. Copyright Land Instruments International.

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5 Contents A1 General Description 1 A2 System Summary 2 A3 Installation Equipment Requirements 3 A3-1 Selecting an Installation Location 3 A3-2 Defining the Installation Pathlength 7 A3-3 Dimensional Information 7 A3-4 Mounting Details 9 A4 Installation 11 A4-1 Installation Checklist 11 A4-2 Mounting Stand-offs 12 A4-3 Mounting Transceiver and Retroreflector 15 A4-4 Local Control Unit Installation 17 A5 Fail Safe Shutter 18 A6 Electrical Installation 19 A6-1 Electrical Connections Overview 19 A6-2 System Cables 21 A6-3 Customer Connection Details to Termination Box 22 A6-4 MODBUS Connections 23 REV 3 April 2004 Publication Number

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7 Contents B1 General Description 24 B2 Getting Started 26 B2-1 The Control Panel 26 B2-2 Function Keys 27 B2-3 Glossary of Terms 28 B2-4 Using the Instrument for the First Time 29 B3 Normal Modes of Operation 46 B3-1 Alarm Setup 46 B3-2 Output Setup 48 B3-3 MODBUS Communications 53 B4 Periodic Modes of Operation 62 B4-1 Calibration Check 62 B4-2 Calibration Audit 63 B4-3 Re-calibration 65 B4-4 Isokinetic Calibration 66 B4-5 M203 Clear Stack Simulator 70 B4-6 M203 Clear Stack Simulator Calibration 75 B4-7 Zero Point Reflector Adjustment 78 B4-8 Upscale Span Filter Adjustment 82

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9 Contents C1 Theory of Operation and Application 85 C1-1 General Outline 85 C1-2 Beer-Lambert s Law 86 C1-3 Optical Pathlength Ratio (OPLR) 87 C1-4 Examples of Different Optical Path Length Correction Ratios (OPLR) 89 C2 Requirements for Environmental Legislation 90 C3 Physical Principles 91 C3-1 General Description 91 C3-2 Principle of Operation 92 C4 User Interface 94 C4-1 Operational Structure 94 C4-2 Faults Screens 95 C4-3 Calibration Screens 96 C4-4 Setup Screens 102 C4-5 Display Screens 116 C4-6 Parameter Screens 118 C5 System Specification 119 C MkII+ Dust and Opacity Monitor 119 C6 Testing and Checking 122 C6-1 Identifying Faults 122 C6-2 Maintenance 124 C6-3 Replacement Parts and Consumables 128 C7 How to Get Further Assistance 133 C8 Configuration Record Sheet 134 Appendix A Aperture & Grating Selection Tables i AppA-1 Automatic Zero Point Reflector Aperture and Grating Selection i AppA-2 Span Filter Grating Selection i Appendix B Low Temperature Termination Box ii AppB-1 Termination Box Heater Unit ii

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11 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A1 General Description The Land Instruments International Model 4500 MkII + Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam through flue gases. An internal microprocessor calculates dust density and other parameters. The instrument comprises the following parts: The Transceiver which contains all of the electronic and electro optic components; the Retro-Reflector containing a corner cube reflector; the Termination Box where the customer terminations are located; and the air purge system. An optional data display Control Room Unit is available. The air purge system can take several forms depending upon individual site requirements. Single and dual electric blowers are available, as are compressed-air driven devices. Continuous purge air supply is essential to prevent dust and corrosive gases from affecting the optical system. Automatic fail safe shutters can also be fitted for temporary protection in the event of a purge air failure. The entire system is designed for continuous operation in all weather conditions, with minimal maintenance. Retro-Reflector Termination Box Transceiver 1

12 DANGER CAUTION Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A2 System Summary The Model 4500 MkII + Dust Opacity Monitoring System comprises the following key components. The use of a Control Room Unit is optional. Weatherproof covers option not shown Model 4500 MkII + Transceiver 2 Model 4500 MkII + Retroreflector 3 Termination Box 4 Air Blower with Filters 5 Umbilical cable 8 6 Instrument Power Input 7 Blower Pressure Switch Trip Output 8 Blower Power Input 9 External Power Isolator 10 External Power Isolator with fuse Important An external circuit breaker incorporating over-current protection or a power isolator and fuse must be fitted. 2

13 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A3 Installation Equipment Requirements A3-1 Selecting an Installation Location IMPORTANT Before fitting the mounting flanges consider the blower type and mounting. The transmissometer should be mounted on the stack or duct so that it can detect a representative concentration of dust across the stack or duct diameter. For new plants, location of the transmissometer should be planned during the design stages; for existing plants, it is critical that the best possible location be selected. If the monitor is to be used for US regulatory compliance, the location should be determined by the EPA installation specifications detailed in 40 CFR 60, Appendix B, Specification 1, or a location approved by the appropriate agency. At the measurement location, there should be as much negative pressure as possible, for example, a stack updraft. The mounting area must have a safe walkway; if necessary, a sufficiently large and accessible platform should be constructed (see below). Measurement errors may result if the transmissometer is exposed to strong vibrations or if the stack or duct changes shape as the gas temperature changes. If these are problems which cannot be avoided, a vibration free mounting can be installed. Land Instruments International can provide recommendations for vibration free mountings upon request. The ambient temperature at the mounting location must remain between -20 C and +55 C (-4 F and 131 F). If necessary, heating, ventilation, or isolation should be used to ensure this temperature range is not exceeded. Measurement Area Platform 3

14 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual Installation Site Requirements Model 4500 MkII (39) 520 (20.5) 240 (10) 240 (10) 320 (13) 1000 (39) (9) 150 (6) (6) 220 (9) 580 (23) 500 (20) 420 (16.5) (9) 220 (9) (7) IMPORTANT Mounting Guidelines Installation Dimensions for Instrument 1. Transceiver 2. Retroreflector 3. Purge air entry 4. Umbilical connector 5. Flange to flange pathlength 6. Transceiver open for calibration audit 7. Retroreflector open for inspection 1. The Transceiver (1) requires approximately 500mm (20 ) minimum distance for installation. 2. The Retroreflector requires approximately 320mm (13 ) minimum distance for installation. 3. Additional clearance is required of approximately 1m (39 ) for mounting and removal procedures. 4. A minimum clearance of 150 mm (6") directly below the instrument is required for purge air and electrical connections. 5. The maximum recommended air hose length between the blower and the air purge is 7m (23ft). Do not exceed this when installing the blower unit(s). 6. The Termination Box must be mounted within 2m (79 ) of the Transceiver in order for the interconnecting cable (4) to reach. Supplied by LAND Instruments International. 7. Measurement Pathlength (5) is factory set and cannot be changed by the user. 8. The Transceiver casing swings open (6), requiring a minimum of 340mm (14 ) to the left hand side of the instrument. 9. The Retroreflector casing also swings open (7), requiring a minimum of 160mm (7 ) to the left hand side of the instrument. 10. IMPORTANT: Ensure that the interconnecting cable has sufficient slack to enable the Transceiver to be swung open. 4

15 Operation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Blank Obsolete content removed 5

16 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual Installation Site Requirements Model 4500 MkII + with Weatherproof Covers 1000 (39) (32) 800 (32) 1000 (39) 730 (29) (29) (32) 660 (26) 800 (32) 900 (35) 5 IMPORTANT Mounting Guidelines Installation Dimensions for Instrument with Weatherproof Covers 1. Weatherproof covers 2. Air purge entry 3. Umbilical connector 4. Flange to flange pathlength 5. Weatherproof covers projection 1. The weatherproof covers require approximately 800mm (32 ) minimum distance for installation on either side of the stack. 2. The weatherproof covers require an additional 1m (39 ) approximately, for mounting and removal procedures. 3. The Termination Box must be mounted within 2m (79 ) of the Transceiver in order for the interconnecting cable (4) to reach. Supplied by LAND Instruments International. 4. Measurement Pathlength is factory set (requirement of EPA certification in the US) and cannot be changed by the user. 5. The weatherproof covers require a minimum of 800mm (32 ) to either side in order to swing open the covers. 6. IMPORTANT: Ensure that the interconnecting cable has sufficient slack to enable the Transceiver to be swung open. 6

17 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A3-2 Defining the Installation Pathlength The installation pathlength is defined as the distance between the Transceiver air purge flange and the Retroreflector air purge flange. This is referred to as the flange-to-flange pathlength. IMPORTANT It is important to set the instrument to the correct pathlength (during manufacture). Failure to do so will affect the accuracy of the measurement readings. Flange-to-Flange Path Length A3-3 Dimensional Information Dimensions of Model 4500 MkII + Dust and Opacity Monitor Weight: Transceiver kg (33.5 lb); Retroreflector kg (16.8 lb) Dimensions of Model 4500 MkII Dust and Opacity Monitor with Fail-safe Shutters (9.8) (15.3) (15.3) 50.0 (2.0) (9.8) (10.6) (10.6) 50.0 (2.0) (9.0) (9.0) (10.0) (9.0) (8.7) (10.0) Weight (with fail-safe shutters): Transceiver kg (42 lb); Retroreflector kg (25.5 lb) 7

18 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual Blank Obsolete content removed 8

19 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A3-4 Mounting Details Air Purge Mounting Holes The air purge unit must be fixed to the mounting flange. It has three mounting holes to accept the mounting studs from the Standpipe. 3 Holes as shown. Dia. 15 on 150.0/5.90 p.c.d. ø190 (7.50) Front view of Air Purge showing mounting holes 9

20 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual Stand-off Flange This assembly is made up of a mounting flange (specially adapted 3" ANSI) attached to a sleeve (standoff), which is used to mount the instruments on the duct. Where required, lengthen or shorten the sleeve to obtain the appropriate measurement pathlength. Unstable mounting bases (such as thin sheet metal walls) may require supplemental reinforcement. See next page for reinforcement detail. Stand-off Flange Assembly (Part Number ) 3 Holes as shown. Dia. 15 on 150.0/5.90 p.c.d. Stand-off Flange Reinforcement 1. Optional Reinforcement (Customer supplied) 1 Stand-off flange with reinforcement Note Before installing mounting flanges, refer also to the Blower installation manual. 10

21 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A4 Installation A4-1 Installation Checklist In order to complete a full installation, check all the listed activities have been undertaken. Selection of installation location Installation of mounting flanges CAUTION Apply purge air before installation of Transceiver and Retroreflector Installation of air blower system - refer to blower instrction manual Connection of purge air supplies to instrument Routing all cables Electrical connection of air blower system Electrical connections for instruments and Termination Box Power up air purge system Connections for control room unit (optional) or any other output devices to Termination Box (i.e. chart recorder, display unit etc.) Check continuity of protective earth Application of purge air followed by installation of the Transceiver and Retroreflector units Power up instrument and calibrate 11

22 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A4-2 Mounting Stand-offs The Model 4500 MkII + is normally supplied with two mounting flanges with sleeves (stand-offs) which are used to mount the transmissometer onto the stack or duct. The sleeves are 240mm (9.45") long. If necessary, shorten or lengthen the sleeves when mounting to obtain the proper measurement path. Unstable mounting bases, such as thin sheet metal walls, may require supplemental bracing (see Mounting Details section A5-4). IMPORTANT Stand-off mounting may be affected by the type of air purge blower unit to be used. Please refer to the installation of blower units for further detail (see section A7). The stand-offs must be mounted so that the Transceiver directly faces the Retroreflector across the centre of the stack or duct. Since most applications involve a vertical stack, the axis common to both flanges must be level or perpendicular to the direction of gas flow. The flange faces must be parallel to within ±1. Accurately mark the centre of each stand-off flange on the stack and punch a locating mark through the liner onto the inner stack plating. Cut a hole from the liner large enough to allow eventual welding of the flange stub to the stack. Then cut a hole through the stack plate material at the punched location mark on the Transceiver unit side of the stack. A 6mm to 12mm (0.25" to 0.50") pilot hole at the Retroreflector locating mark can also be cut at this time. Ensure that the TOP label is in the 12 o'clock position and tack weld the Transceiver stand-off into place. The stand-off flange must be parallel to the stack wall. Care must be taken at this stage, or subsequent instrument alignment may be impossible. TOP Mounting stand-offs with reinforcement 12

23 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual Cut a hole around the Retroreflector pilot hole, large enough to allow eventual welding of the outside of the flange stub to the stack wall. The mounting flange plate must be parallel to the stack wall. IMPORTANT The Model 4500 MkII + Dust/Opacity Monitor is factory set to the flange-to-flange measuring path as specified by the customer at the time of order. This measurement is indicated on the back of the Transceiver. During the welding and alignment procedures, be sure the flange-to-flange measurement path does not differ by more than ±1% from that specified on the Transceiver. If the measuring path is easily accessible and short enough, the flanges can be aligned with a straight piece of tube. First slide the tube through both flanges. Then, ensuring the specified flange-to-flange measuring path is maintained to within ±1%, tack weld the Retroreflector stand-off flange in place. Make the necessary adjustments and weld the Transceiver stand-off flange in place. Finally, make any necessary adjustments and fully weld the Retroreflector stand-off flange in place. Flange to flange pathlength Alignment Tube Mounting flange alignment When the measurement length is too long to use an alignment pipe, Land Instruments International can supply an optical flange alignment tool (Part number ). Contact Land Instruments International if this part is required. 13

24 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual Flange Alignment Tool (Optional) The flange alignment tool (Part number ) consists of two plates which are mounted to the flanges. One plate supports a light source, and the other plate supports a small telescope with a circle in the centre. When the flanges are properly aligned, the light spot must be located in the centre of this circle (see below). Light Source Alignment Circle Light Source Stand-off Flange 2 Stand-off Flange 1 The flange alignment tool is used as follows: Flange alignment tool 1. Remove the disc springs from the standpipe flange and store. 2. Tack weld the flanges. 3. Mount the flange alignment tool as shown above. 4. Align flange number 1 and weld it into place. 5. Reverse the flange alignment tool (switch components). 6. Align flange number 2 and weld it into place. 7. Replace the disc springs, observing correct orientation. (each stud requires 6 pairs of disc springs). During the welding and alignment procedures, be sure the flange-to-flange pathlength is accurately maintained to within ±1% of that specified on the Transceiver. 14

25 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A4-3 Mounting Transceiver and Retroreflector 1 This procedure is best performed when the process is not operating and the stack is cold. 2 If the process is operating, and especially if the stack pressure is above atmospheric, the air purge system should be connected to the Transceiver and Retroreflector and switched on, before the instrument is mounted on to the flanges. 3 Check that each mounting stud has six pairs of spring washers (1), each pair opposed as illustrated below. On top of the six washers, next to the M12 nut (3), should be a hemispherical washer (2) with the flat side towards the M12 nut Ensure that the rubber sealing bands are replaced loosely around the front sections of the Transceiver and Retroreflector. Continue on next page. 15

26 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual 5 Remove the three M12 nuts (4) from the Transceiver mounting flange (1), and locate the Transceiver purge flange (2) on to the studs (3). Replace the Nyloc nuts (4) and tighten them, compressing the spring washers (5), until there is a gap of 13mm (½ ) between the two flanges (1 and 2), all round. Pull the sealing band (6) into place over the gap (½") Install the Retroreflector as on 5 above. CAUTION Ensure that the air purge system is connected and operating, even if the instrument is not in use. 16

27 Model 4500 MkII + Dust and Opacity Monitor Operation and Maintenance Manual A4-4 Local Control Unit Installation The connection interface of the Land Instruments International Model 4500 MkII + Dust and Opacity Monitor is the Termination Box (T-Box). The T-Box is protected to IP65(NEMA4) and should be mounted on a flat vertical surface, within 2.0 metres (6 feet) of the Transmissomter (to allow the interconnection cable to reach). Mark out the position and secure with four M12 (½ ) bolts and washers (Customer Supplied). 2 slots Ø8.5 (0.3) 210 (8.3) 180 (7.0) DANGER CAUTION 300 (11.8) 400 (15.8) 2 holes Ø8.5 (0.3) 120 (4.7) A blank removable plate is provided on the bottom of the T-Box allowing the customer choice of cable entry type. CAUTION The warranty on the instrument may be invalidated if entry fittings are not rated to IP65/NEMA4 and damage occurs due to entry of water or other substances. The wiring to the T-Box includes power connections to the Transceiver, cables to the optional fault indicators (blower pressure switches, etc.), two analogue outputs, alarm and status relay outputs. Automatic calibration cycles can be initiated by the T-Box. The customer may prefer to have an external device initiate the calibration cycle (for instance, when used with other Continuous Emissions Monitoring System or Continuous Opacity Monitoring Systems). This can be achieved by placing a contact closure across Din Rail terminals 36 and

28 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual A5 Fail Safe Shutter The Fail Safe Shutter Air Purge Units protect the optical surfaces from corrosive stack gases in the event of air supply failure. Protective shutters are opened by the air pressure from the Air Blower Units to allow normal operation of the instrument. If the air supply fails, the air pressure drops and the shutters close via a counter weight mechanism as illustrated below. NOTE Shutters provide temporary protection only. If there is prolonged air failure the Transceiver and Retroreflector should be removed (Side View) (Front View) Fail Safe Shutter Air Purge Unit Key. 1. Protective Safety Shutter (open position) 2. Counter weight (open position) 3. Control Blade (open position) 18

29 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor A6 Electrical Installation A6-1 Electrical Connections Overview All switch cabinets, distribution boxes, fuses and other components for electrical installation must be provided by the customer, as must the mains power supply connections. Installation should be carried out by a competent person and cables should satisfy current carrying capacity and voltage rating. Mains Supply The following mains power supply connections must be made for: Termination Box (T-Box) Air Blower Unit/s Control Room Unit (optional) Additional equipment (i.e. chart recorder etc.) Signal Connections The following signal cables must be connected via the Termination Box: Umbilical cable to Transciever Air Blower pressure switch interconnections Control Room Unit (optional) Customer Alarms Current Loop Maintenance Switch Optional Connections The following cable connections must be made where required by the application Status relay connections Serial data communications Air Blower Motor Connections Refer to the instruction manual for each blower. 19

30 DANGER CAUTION Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Electrical Connections Overview The system is connected as illustrated in the diagram below Electrical Connections System Overview 1 Model 4500 MkII + Transceiver 2 Model 4500 MkII + Retroreflector 3 Termination Box 4 Air Blower with Filters 5 Umbilical cable 6 Instrument Power Input 7 Blower Pressure Switch Trip Output 8 Blower Power Input 9 External power isolator 10 External power isolator with fuse 20

31 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor A6-2 System Cables The following list of cable types (see diagram previous page) is recommended by Land Instruments International: Electrical No. of Core Size Core Size Core Size Screened Supplied Connections Cores mm 2 strands/dia awg By Overview / YES LAND to /0.2 to 56/ to 12 NO Customer to /0.2 to 30/ to 16 NO Customer / NO Customer 1 DANGER CAUTION

32 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual A6-3 Customer Connection Details to Termination Box IMPORTANT Isolate the mains supply before making any connection to the Termination Box. This instrument must be earthed/grounded. Cable entries are not supplied as standard. The blank plate may be removed and cut out for suitable conduit or other type of entry. Terminal No. Function Designation 1 Mains Power Live 2 Neutral 3 Earth 4 Current Loop O/P 1 +ve 5 screen 6 -ve 7 Current Loop O/P 2 +ve 8 screen 9 -ve 10 System OK Fault 11 Common 12 OK 13 Alarm 1 OK 14 Common 15 Alarm Active 16 Alarm 2 OK 17 Common 18 Alarm Active 19 Zero Calibration Run 20 Common 21 In Progress 22 Span Calibration Run 23 Common 24 In Progress 25 Maintenance Run 26 Common 27 Maintenance 28 Blower Fail #1 Input 29 Return 30 Blower Filter Blocked #1 Input 31 Return 32 Blower Fail #2 Input 33 Return 34 Blower Filter Blocked #2 Input 35 Return 36 Calibration Trigger Input 37 Return 38 Modbus Y (Tx) 39 RS485 / RS232 Z(/Tx) 40 see section A6.5 for details A (Rx) 41 B (/Rx) 42 Common 43 Screen 22

33 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor A6-4 MODBUS Connections The communication protocol offered as an option on the Model 4500 MkII + is the MODBUS protocol. Based on the RS232/RS485 three wire half duplex hardware standard it provides direct access to system data via the T-Box terminal connections The MODBUS PCB is manufactured to accept RS 232 or RS 485 connection using the switch selector fitted inside the termination box. The switch is located inside the T-Box, and is clearly labelled. IMPORTANT Where RS 232 is selected as the Modbus communications protocol, the existing 120 Ω termination resistor requires disconnecting between terminals 40 and 41 inside the T-Box. The resistor must be retained for RS 485 Modbus communications. WARNING Isolate the mains supply before making any electrical adjustments to the T-Box. This instrument must be earthed/grounded. RS 232 RS 485, 4 Wire, full duplex RS 485, 2 Wire, half duplex (Tx) (Rx) COM Y (Tx) A (Rx) COM Z (/Tx) B (/Rx) (Tx) (/Tx) (Rx) (/Rx) COM (Rx) (Tx) Common A (Rx) Y (Tx) A B Common B (/Rx) Z (/Tx) REMOTE DEVICE REMOTE DEVICE Common REMOTE DEVICE 23

34 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B1 General Description The Land Instruments International Model 4500 MkII + Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam through flue gases. An internal microprocessor calculates dust density and other parameters. The instrument comprises the following parts: The Transceiver which contains all of the electronic and electro optic components; the Retro-Reflector containing a corner cube reflector; the Termination Box where the customer terminations are located; and the air purge system. An optional data display Control Room Unit is available. The air purge system can take several forms depending upon individual site requirements. Single and dual electric blowers are available, as are compressed-air driven devices. Continuous purge air supply is essential to prevent dust and corrosive gases from affecting the optical system. Automatic fail safe shutters can also be fitted for temporary protection in the event of a purge air failure. The entire system is designed for continuous operation in all weather conditions, with minimal maintenance. Retro-Reflector Termination Box Transceiver 24

35 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Analogue Output The Model 4500 MkII + Dust and Opacity Monitor has two current loop outputs available. Each one may be set independent of the other to output one of the six functions below: Opacity Constant Current Optical Path Length Ratio Dust Calibration Drift Optical Density All the options can be set to TRACK or HOLD the measurement signal during calibration routines. If TRACK is set, the measurement signal will continue to be output during calibration and if HOLD is set the measurement signal will remain at the last recorded reading before calibration until the calibration routine is complete. Relay Outputs Located on the key panel of the 4500 MkII + are five LED s which light to indicate the operation of the following relay outputs: System OK Zero Calibration In Progress Span Calibration in Progress 2 Alarms Remote Calibration Initiation Calibration of the monitor may be initiated remotely from the optional Control Room Unit (panel or wall mounted) or via Modbus control. Computer Interface Operation The Model 4500 MkII + Dust and Opacity Monitor may be connected to a computer or data acquisition system via an RS232 or RS485 Modbus interface inside the Termination Box. 25

36 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B2 Getting Started B2-1 The Control Panel The Model 4500 MkII + is operated from the User Interface in the Transceiver. The User interface is operated via various function keys. It has five illuminated indicators, a contrast control and a maintenance key. The liquid crystal display normally indicates the opacity measured by the instrument. Error messages and other parameters can also be displayed, as explained in a later section. The displayed opacity is corrected for Optical Path Length Ratio (OPLR) sometimes referred to as Pathlength Correction Factor (PLCF) (OPLR = 0.5 x PLCF) The OPLR is factory set and cannot be changed by the customer (see section C1-3) User Interface Key 1. System status 6. Contrast control 2. Alarm 1 status 7. LCD 3. Alarm 2 status 8. Maintenance key 4. Zero Calibration in progress 9. Menu exit key 5. Span Calibration in progress 10. Function keys 26

37 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor B2-2 Function Keys The following function keys are located on the user interface. Key ENTER or or Function Generally used for selecting menu items and for making and saving changes. Scrolls the main and secondary menus Scrolls sub menus and selects/alters parameters for changes EXIT Returns to the previous menu level. Maintenance Key - the instrument must be unlocked before any parameter setup or adjustment can take place. Contrast Control Maintenance Key Operation The instrument is unlocked by holding the key down for a period of 3 seconds. Once unlocked the red LED will illuminate. The instrument will then request a password. The default password is 10. To return the instrument to normal operation, the key must be pressed for 1 second. The red LED will then go off. NOTE No Modbus communication is possible whilst the instrument is unlocked. Contrast Key Operation The Contrast control should be used to vary the LCD display contrast. Press + to increase contrast Press - to decrease contrast 27

38 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B2-3 Glossary of Terms Op...Opacity O.D....Optical Density Dust...Dust Density Averaging 1...Time period used to calculate block average of output 1 Averaging 2...Time period used to calculate block average of output 2 Status... System Status Faults Loop O/P 1...Current loop output 1 reading in ma Loop O/P 2...Current loop output 2 reading in ma Last Zero...Last zero calibration value Last Span... Last span calibration value Cal. Drift...Drift of signal between calibrations (range 0.1 to 1.0) Version...Software Version Number Blank... A blank line So...Signal Detector Offset Sf...Signal Detector Flood Value Sm... Signal Detector Measurement Ro...Reference Detector offset Rf...Reference Detector Flood Value Rm... Reference Detector Measurement C... Calibration Constant X... Calibration constant B... Balance correction G... Gain correction factor Q... Uncorrected transmission factor Dust Gain... Constant relating Optical Density to Dust Density. Dust Offset...Optical Density v Dust Density zero offset (usually zero) Zero Damper...Low pass digital filter applied to zero reading Flood Damper... Low pass digital filter applied to flood LED Cal Damper...Low pass digital filter applied to calibration OP 1 Damper...Low pass digital filter applied to output 1 OP 2 Damper...Low pass digital filter applied to output 2 PLCF... Path Length Correction Factor OPLR... Optical Path Length Ratio Last Cal...Data stored from the latest calibration Zero Comp....Opacity compensation due to dust build on the lens Isokinetic O.D.... Average Optical Density calculated during gravimetric test Running In...Positioning the zero reflector or upscale filter to an active position Running Out... Positioning the zero reflector or upscale filter to an inactive position 28

39 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor B2-4 Using the Instrument for the First Time The following instructions must be adhered to for the correct running of the instrument. 1. Complete Installation Ensure installation has been completed, including any optional equipment e.g. Control Room Unit (CRU). 2. Check Display is Legible Once the instrument is powered up, check that the LCD display has acceptable visibility. Adjust the display contrast using the key as appropriate. 3. Check the Optical Pathlength Ratio. See section C1-3.. Faults: Parameters: So: 0 Check the OPLR is correct and then continue to align the instrument. 1. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates. 2. Enter the password using the and keys, then press Enter. The default password is Scroll through the menu spine using the and keys until PARAMETERS is displayed then press the ENTER () key. OPLR: 0.5 EXIT Parameters: 4. Scroll through the PARAMETERS menu using the and keys until OPLR is displayed. 5. If the OPLR is correct press the EXIT key to return to the menu spine. If it is incorrect, the instrument must be returned to Land Instruments International for reprogramming. Now set the instrument to alignment mode. 29

40 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 4. Set the Instrument to Align Mode Accurate alignment is essential if the Model 4500 MkII + is to function correctly and meet its design specification. Faults: 1. Scroll through the menu spine using the and keys until SETUP is displayed then press the ENTER () key. Setup: Outputs: 2. Scroll through the SETUP menu using the and keys until Miscellaneous is displayed and then press the ENTER () key. Miscellaneous: Align: Align Mode Signal: The word Align should now be displayed (if not use the and keys to scroll through the Miscellaneous menu until Align is displayed). Press the ENTER () key and a Signal value is displayed, the instrument is now in Align mode. In Align mode, the normalisation function is disabled so that the measurement LED appears to be lit constantly, thereby assisting visual alignment using the alignment targets on the Transceiver and Retro- Reflector. In addition the word 'Signal' followed by a number proportional to the measured intensity is displayed on the LCD display. Now align the Retro-Reflector. 30

41 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 5 Align the Retro-Reflector Quick Release Clip Captive Socket Head Screws Opening the Retro-Reflector Case and Releasing the Reflector 1. Open the Retro-Reflector case by undoing the two quick-release clamps. 2. Release the Retro-Reflector Mount by unscrewing the two captive socket head screws on either side of the Retro-Reflector Mount and allow the Retro-Reflector to drop into a horizontal position. 3. Close the case and fasten the quick-release clamps WARNING Retro-Reflector Alignment Target Eye and face protection must be worn when looking into hot gases. 4. Observe the alignment target through the window (3). A bright green spot (4) should be visible. 31

42 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 5. If the green spot is not visible undo the quick release clamps on the Retro-Reflector and look down the purge barrel. The bright green light from the Transceiver should be clearly visible. If not, then the Transceiver is either grossly misaligned or the instrument is malfunctioning. 6. To move the green spot horizontally adjust the M12 nut (1) on the air purge flange and to move it vertically, adjust the M12 nuts (2), also on the air purge flange as illustrated above. Adjust these nuts until the green spot is central in the inner circle. 7. In bright sunshine the green spot on the alignment target may not be visible. In this case return to the Transceiver, undo the quick release clamps and swing the instrument away from the purge. It should now be possible to adjust the Retro-Reflector until the bright circle of sunlight, visible through the Transceiver purge unit, is centred on the target. 8. Ensure that the 6 pairs of spring washers between the air purge flange and the mounting flange are under moderate tension. It is important that the instrument is firmly held in place to maintain optical alignment. 9. Open the Retro-Reflector case and re-fix the Retro-Reflector in position by tightening the captive socket head screws. Close the Retro-Reflector case and fasten the two quick-release clamps. 10. Now align the Transceiver. 32

43 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 6 Align the Transceiver Transceiver Alignment Target 1. Observe the alignment target through the window (3). A bright green spot (4) should be visible. 2. To move the green spot horizontally adjust M12 nut (1) on the air purge flange and to move it vertically, adjust the M12 nuts (2), also on the air purge flange as illustrated above. Adjust these nuts until the green spot is inside the inner circle. 3. In bright sunshine the green spot on the alignment target may not be visible. In this case return to the Retro-Reflector, undo the quick release clamps and swing open the rear cover. It should now be possible to adjust the Transceiver until the bright circle of sunlight, visible through the Retro-Reflector purge unit is centred on the target. Close the Retro-Reflector again. If the green spot is visible, adjust the nuts until it is central within the inner circle. If this is not possible, then adjust for maximum signal level. 4. Ensure that the 6 pairs of spring washers between the air purge flange and the mounting flange are under moderate compression. If the compression becomes excessive, it is likely that the third nut has been over tightened or the mounting flange may not have been fitted accurately. 5. On the User interface press the Maintenance key and hold for 1 second to exit. The red LED will be extinguished. Once the instrument has been correctly aligned configure the calibration options. 33

44 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 7. Setup Calibration Check Intervals The Model 4500 MkII + Dust and Opacity Monitor may be programmed to perform a calibration check at preset intervals. Alternatively the timer can be disabled (set time interval to zero) and the instrument will calibrate only in response to an external trigger (momentary contact closure across terminals 36 and 37 inside the Termination Box). 1. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates. Faults: 2. Enter the password using the and keys, then press Enter. The default password is Scroll through the menu spine using the and keys until CALIBRATION is displayed then press the ENTER () key. Calibration: Cal check: Cal Setup: 4. Scroll through the CALIBRATION menu using the and keys until Cal Setup is displayed and then press the ENTER () key. Interval: 24h Interval: 10 EXIT Cal Setup: 5. The word Interval is displayed (if not use the and keys to scroll through the menu until Interval is displayed). Press the ENTER () key (notice the underlined character). Now select the interval between automatic calibration checks by pressing the and keys. Once selected press the ENTER () key to set the value and the EXIT key to return to the Cal Setup display. Continue with calibration setup. 34

45 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Cal Setup: 6. Press the ENTER () key from the Cal Setup display to return to the Cal Setup menu. Scroll through the Cal Setup menu using the and keys until Time To Next Cal is displayed and then press the ENTER () key (notice the underlined character). Time To Next Cal 0 h 0 mins Time To Next Cal 0 h 0 mins Time To Next Cal 3 h 0 mins 7. Press the and keys to select the number of hours to wait before performing the first automatic calibration check, and then press the ENTER () key (notice the underlined character has changed). Now press the and keys again, this time to select the number of minutes (added to the hours) to wait before performing the first automatic calibration check. Press the EXIT key to set and return to the Cal Setup display. EXIT Cal Setup: EXIT 8. Press the EXIT key again to return to the menu spine and turn the Maintenance key to RUN (No LED). Now setup the current loop outputs. Calibration: 35

46 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 8. Setup Current Loop Outputs The Model 4500 MkII + Dust and Opacity Monitor has two independent customer outputs available. Each signal output interval may be altered by setting the Average 1 and Average 2 displays accordingly. 1. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates. Faults: 2. Scroll through the menu spine using the and keys until SETUP is displayed then press the ENTER () key. Setup: Outputs: 3. The word Outputs is now displayed (if not use the and keys to scroll through the menu until Outputs is displayed). Now press the ENTER () key. Output 1: 4. The word Output 1 is now displayed (if not use the and keys to scroll through the menu until Output 1 is displayed). Press the ENTER () key and the Opacity option is displayed (this may vary if previously altered), press the ENTER key again (notice the underlined character). Outputs 1: Opacity Continue with output setup. Outputs 1: Opacity 36

47 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Outputs 1: Opacity Outputs 1: OD 5. Use the and keys to select the required option for Output 1 and then press the ENTER () key (notice no underlined character). Press the and keys to scroll to the Range option and press the ENTER () key again to display the underlined character (The Constant Current option is used for diagnostic purposes and is detailed in section B3-5). Outputs 1: Range: Press the and keys to select the maximum reading to be allocated to the maximum output and then press the ENTER () key (notice no underlined character). Now press the and keys again to select the During Cal option and press the ENTER () key. Outputs 1: Range: 3.0 Outputs 1: During Cal: Outputs 1: During Cal: TRACK HOLD 7. Using the and keys select TRACK (to continue the output signal during automatic calibration checks) or HOLD (to retain the last reading before the automatic calibration check until the calibration is completed). Press the ENTER () key to set the option (notice no underlined character) and then the press EXIT key to return the display to Output 1. EXIT Output 1: 37

48 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Output 1: Output 2: 8. To set the second customer output, use the and keys to select Output 2 and then press the ENTER () key. Repeat steps 4 to 6 previous. 9. From the Output 1 or Output 2 display press the and keys to select the Averaging 1 display and then press the ENTER () key. Press the ENTER () key again (notice the underlined character). Averaging 1: OFF 0h 0m 0s Averaging 1: OFF 0h 0m 0s 10. If the Averaging 1 option is set to OFF the Output 1 signal is continuously output. If the Averaging 1 is set to ON the Output 1 signal is averaged over the selected period. Press the and keys to select ON to average the output (Set to OFF if not required) and press the ENTER () key. Averaging 1: ON 0h 0m 0s Averaging 1: ON 0h 0m 0s 11. Set the hours (h) by pressing the and keys and then the ENTER () key. Set the minutes (m) and seconds (s) in a similar way. Averaging 1: ON 6h 0m 0s Averaging 1: ON 6h 45m 0s Averaging 1: ON 6h 45m 59s 38

49 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Averaging 1: ON 6h 45m 59s 12. Once the required averaging time period has been selected and set, press the EXIT key to return to the Averaging 1 display. EXIT Averaging 1: 13. To set the averaging option for the second customer output, use the and keys to select Averaging 2 and then press the ENTER () key twice (notice the underlined character). Repeat steps 10 to 12 previous. Averaging 2: Averaging 2: ON 6h 45m 59s 14. Press the EXIT key twice to return to the menu spine. Now setup the alarms. EXIT Setup: EXIT Outputs: 39

50 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 9. Setup Alarms The Model 4500 MkII + has two customer alarms available. Each alarm may be set to trip at a specified level for Optical Density, Opacity or Dust. A delay of between 0 to 30 seconds is also available for each alarm. 1. Scroll through the menu spine using the and keys until SETUP is displayed then press the ENTER () key. Faults: Setup: 2. Scroll through the SETUP menu using the and keys until Alarms is displayed and then press the ENTER () key. Outputs: Alarms: Alarm 1: 3. The word Alarm 1 should now be displayed. Press the and keys to select between the two available alarms, Alarm 1 and Alarm 2 and then press the ENTER () key. The alarm type (AL1 type) is now displayed as Opacity (this may vary if previously adjusted). Press the ENTER key again (notice the underlined character). AL1 type: Opacity AL1 type: Opacity 40

51 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor AL1 type: Opacity AL1 type: O.D. 4. Use the and keys to select the required measurement (Optical Density, Opacity or Dust) to be alarmed and then press the ENTER () key (notice no underlined character). Press the and keys to scroll to the AL1 trip (or AL2 trip if setting Alarm 2 ) option and press the ENTER () key again (notice the underlined character). AL1 trip: Press the and keys to select the required level at which the alarm is to trip and then press the ENTER () key (notice no underlined character). Now press the and keys again to select the Delay option and press the ENTER () key (notice the underlined character). AL1 trip: Delay: 5s 6. Using the and keys select the required time period for the Alarm to be delayed and press the ENTER () key (notice no underlined character). Press the EXIT key twice to return to the menu spine. Now perform a Calibration Check Delay: 10s EXIT Alarm 1: 41

52 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 10 Perform Calibration Check The instrument will be ready for use on completion of Cal check. The simplest way to perform this is as follows: 1. Power down the instrument. 2. Power up the instrument and a calibration check will be performed automatically. 3. Allow three minutes for the calibration check to be completed and then check that the System OK LED is on. 4. The Model 4500 MkII + is now in operation. NOTE The current loop outputs will initially read zero until the first averaging period is complete. If the MODBUS option is used continue with setup, otherwise, the instrument is ready for operation. 42

53 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 11 MODBUS Option MODBUS is a communications system based on the RS232/RS485 hardware standard and provides direct access to the Model 4500 MkII + system data via the Termination Box. It is a standard feature on this model. Details are available from the Modbus website: The instrument is factory set to RS232. Where RS485 is required, the switch (fitted inside the Termination Box) must be moved to the lower position. The switch is situated on the underside of the board adjacent to the label (as illustrated). It has two positions. RS232 - Up RS485 - Down Three LEDs situated on the underside of the main board (inside the T-Box) will flash when is is fully functional. This provides a visual indication that the Modbus system is working. The light from the LEDs is clearly visible, reflected by the right hand side of the case Troubleshooting If problems arise when setting up the Modbus communications then go through the following checklist. 1. Check the Station number is 1 and the Link Not Fitted are correct in the instrument settings. 2. If you are using RS232 and one LED is permanently ON, then check the selector switch is in the Up position. 3. If you are using RS485 and no LEDs are ON, then check the selector switch is in the Down position. IMPORTANT Modbus communications are not possible when the instrument is in maintenance mode. 43

54 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Setup Menu MODBUS Options Set Station Number and Link options on the Miscellaneous menu under Setup on the menu spine (see section C4-4 Setup Screens). The Model 4500 MkII + has two options that require setting for correct use of the MODBUS communications protocol. 1. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates. Faults: 2. Scroll through the menu spine using the and keys until SETUP is displayed then press the ENTER () key. Setup: Outputs: 3. Scroll through the SETUP menu using the and keys until Miscellaneous is displayed and then press the ENTER () key. Miscellaneous: Align: 4. Scroll through the Miscellaneous menu using the and keys until Station number is displayed and then press the ENTER () key (notice the underlined character). NOTE: Station Number should be set to 1. Station number: x Station number: x 44

55 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Station number: x Station number: x Link: Not fitted 5. The Station Number indicates the location of the instrument to the user control system via the MODBUS communication protocol. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). 6. Scroll through the Miscellaneous sub-menu again by pressing the keys until the Link option is displayed and then press the ENTER () key (notice the underlined character). NOTE: Should be set to Link not fitted. Link: Not fitted Link: Not fitted 7. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. 8. Press the EXIT key to return to the SETUP menu and then again to return to the Menu Spine. Instrument is now ready for operation. EXIT EXIT Setup: 45

56 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual B3 Normal Modes of Operation B3-1 Alarm Setup The Model 4500 MkII + has two customer alarms available. Each alarm may be set to trip at a specified level for Optical Density, Opacity or Dust. A delay of between 0 to 30 seconds is also available for each alarm. Faults: 1. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates. 2. Scroll through the menu spine using the and keys until SETUP is displayed then press the ENTER () key. Setup: Outputs: 3. Scroll through the SETUP menu using the and keys until Alarms is displayed and then press the ENTER () key. Alarms: Alarm 1: AL1 type: Opacity 4. The word Alarm 1 should now be displayed. Press the and keys to select between the two available alarms, Alarm 1 and Alarm 2 and then press the ENTER () key. The alarm type (AL1 type) is now displayed as Opacity (this may vary if previously adjusted). Press the ENTER key again (notice the underlined character). Continue to step 5. AL1 type: Opacity 46

57 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor AL1 type: Opacity 5. Use the and keys to select the required measurement (Optical Density, Opacity or Dust) to be alarmed and then press the ENTER () key (notice no underlined character). Press the and keys to scroll to the AL1 trip (or AL2 trip if setting Alarm 2 ) option and press the ENTER () key again (notice the underlined character). AL1 type: O.D. AL1 trip: Press the and keys to select the required level at which the alarm is to trip and then press the ENTER () key (notice no underlined character). Now press the and keys again to select the Delay option and press the ENTER () key (notice the underlined character). AL1 trip: Delay: 5s 7. Using the and keys select the required time period for the Alarm to be delayed and press the ENTER () key (notice no underlined character). Press the EXIT key to return the display to Alarm 1. Delay: 10s EXIT Alarm 1: 8. Press and hold the Maintenance key fro 1 second to return to RUN mode (no LED illuminated). The instrument alarms are now set. 47

58 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual B3-2 Output Setup The Model 4500 MkII + Dust and Opacity Monitor has two independent customer outputs available. Each signal output interval may be altered by setting the Average 1 and Average 2 displays accordingly. 1. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates. Faults: 2. Scroll through the menu spine using the and keys until SETUP is displayed then press the ENTER () key. Setup: Outputs: Output 1: Outputs 1: Opacity 3. The word Outputs is now displayed (if not use the and keys to scroll through the menu until Outputs is displayed). Now press the ENTER () key. 4. The word Output 1 is now displayed (if not use the and keys to scroll through the menu until Output 1 is displayed). Press the ENTER () key and the Opacity option is displayed (this may vary if previously altered), press the ENTER key again (notice the underlined character). Continue to step 5. Outputs 1: Opacity 48

59 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Outputs 1: Opacity Outputs 1: OD 5. Use the and keys to select the required option for Output 1 and then press the ENTER () key (notice no underlined character). Press the and keys to scroll to the Range option and press the ENTER () key again to display the underlined character (The Constant Current option is used for diagnostic purposes and is detailed in section B3-5). Outputs 1: Range: Press the and keys to select the maximum reading to be allocated to the maximum output and then press the ENTER () key (notice no underlined character). Now press the and keys again to select the During Cal option and press the ENTER () key. Outputs 1: Range: 3.0 Outputs 1: During Cal: Outputs 1: During Cal: TRACK HOLD 7. Using the and keys select TRACK (to continue the output signal during automatic calibration checks) or HOLD (to retain the last reading before the automatic calibration check until the calibration is completed). Press the ENTER () key to set the option (notice no underlined character) and then the press EXIT key to return the display to Output 1. Continue to step 8. EXIT Output 1: 49

60 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual Output 1: 8. To set the second customer output, use the and keys to select Output 2 and then press the ENTER () key. Repeat steps 5 to 7 above. Output 2: Outputs 2: Opacity Outputs 1: 9. From the Output 1 or Output 2 display press the and keys to select the Averaging 1 display and then press the ENTER () key. Press the ENTER () key again (notice the underlined character). Averaging 1: OFF 0h 0m 0s Averaging 1: OFF 0h 0m 0s Averaging 1: ON 0h 0m 0s 10. If the Averaging 1 option is set to OFF the Output 1 signal is continuously output. If the Averaging 1 is set to ON the Output 1 signal is averaged over the selected period. Press the and keys to select ON to average the output (Set to OFF if not required) and press the ENTER () key. Continue to step

61 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Averaging 1: ON 0h 0m 0s 11. Set the hours (h) by pressing the and keys and then the ENTER () key. Set the minutes (m) and seconds (s) in a similar way. Continue to step 12 Averaging 1: ON 6h 0m 0s Averaging 1: ON 6h 45m 0s Averaging 1: ON 6h 45m 59s 51

62 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual Averaging 1: ON 6h 45m 59s 12. Once the required averaging time period has been selected and set, press the EXIT key to return to the Averaging 1 display. EXIT Averaging 1: 13. To set the averaging option for the second customer output, use the and keys to select Averaging 2 and then press the ENTER () key twice (notice the underlined character). Repeat steps 9 to 11 above. Averaging 2: Averaging 2: OFF 0h 0m 0s EXIT EXIT 14. Press the EXIT key twice to return to the menu spine and then press the maintenance key for 1 second to switch into RUN mode (no LED illuminated). The instrument outputs are now set. Setup: 52

63 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor B3-3 MODBUS Communications MODBUS is a communications system based on the RS232/RS485 three wire half duplex hardware standard and provides direct access to the Model 4500 MkII + system data via the instrument serial port. MODBUS can be used to: a) read any of the parameters measured by the Instrument b) check the instrument status c) initiate a check cycle calibration NOTE Changing the calibration constants may fundamentally affect the operation of the instrument. The instrument functions as a MODBUS slave device in accordance with the MODBUS protocol (as defined by Modicon) Details of the MODBUS standard are available from Before communicating with Model 4500 MkII + via the MODBUS interface, it is necessary to set the Station No. (the MODBUS slave address) and the Link options to an appropriate value. The two options are located in the Miscellaneous menu under Setup on the menu spine (see Setup Screens section C4-4). The system data for the Model 4500 MkII + is accessible via register numbers as shown on the System Data Register Table shown in this section. NOTE There is a possible source of confusion in the definition of Register Numbers used in MODBUS functions. For historical reasons, user reference numbers are expressed as decimal numbers with a starting offset of 1; so a Modbus message requesting a read at Address Offset 0 would return the value in Register 1. The System Data Register Table given uses Register Numbers rather than address offsets. 53

64 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual Commands Mobus communications will be limited to the following command subset: Command MODBUS Function Notes 03 Read Holding Register Read Register (single or block) 06 Pre-set Register Write to Single Register 10 (Hex) Pre-set Multiple Registers Write to Multiple Registers NOTE Registers (03) The block read command is limited to a maximum of 10 registers (06) Only one register at a time may be changed with this command (10 Hex) Required in order to change floating point or 32 bit variables, which span two registers A MODBUS register holds a 16 bit data value. The following table indicates the range of data types that the system parameters encompass, with a description of how they are accessed as registers. Variable Type Character Integer Long Floating Point Description 8 bit. As the minimum data size is 16 bit, character variables (such as system status) will reside in the lower 8 bits of the returned register value. 16 bit. Single register. 32 bit. These will be placed in two consecutive registers, MSB first. 32-bit variables located in two consecutive registers. IEEE Standard Floating Point Notation. 54

65 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor System Data Register Table NOTE Certain registers are read-only. Any attempt to write to these registers will result in the return of an error code. Register # Parameter Data Description Range Write Type Access 25 OPLR Float Optical Path Length Ratio NO 26 (Previously PLCF) 49 Opacity Float Calculated opacity NO Optical Density Float Calculated optical NO 52 density 53 Dust Density Float Calculated dust NO 54 density 55 Average Optical Float Average optical density NO 56 Density during gravimetric test 65 Cal Check OPz Float Cal check zero opacity NO 66 value 67 Cal Check OP0 Float Cal check opacity value NO Cal Check Float Cal check span opacity NO 70 Upscale value 85 Cal Timer 16-bit Calibration timer counter NO (seconds) 86 Motor Timer 16-bit Motor timer counter (5mS) NO 87 Error Flags 32-bit Error flags* NO System State 8-bit System status* YES 105 System Mode 8-bit System operating mode* NO 106 Cal Status 8-bit Calibration status* NO For registers marked * see over page 55

66 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual Register # Parameter Data Description Range Write Type Access 110 OP1 Span Float CLOP 1 range YES 111 Optical Density optical density 112 OP1 Span Float CLOP 1 range YES 113 Opacity opacity 114 OP1 Span 16-bit CLOP 1 range YES Dust dust density 115 OP1 Average Float CLOP 1 average value Dependent on YES 116 units of output (see registers 49 to 53) 122 OP1 Bits 16-bit CLOP 1 output bits scaled NO 4095 = 20mA 126 OP1 Output 8-bit CLOP 1 output units* YES 133 OP2 Span Float CLOP 2 range YES Optical Density optical density 134 YES 135 OP2 Span Float CLOP 2 range YES Opacity opacity 136 YES 137 OP2 Span Dust 16-bit CLOP 2 range YES dust density 138 OP2 Average Float CLOP 2 average value Dependent on YES 139 units of output (see registers 49 to 53) 145 OP1 Bits 16-bit CLOP 2 outputs bits scaled NO 4095 = 20mA 149 OP2 Output 8-bit CLOP 2 output units* YES 166 Start Calibration 16-bit Start Calibration Normally 0 YES 1 - Initiate Cal. 167 Output Relays 16-bit Output relays* - NO 168 Calibration Phases 16-bit Calibration Phases - NO For registers marked * see over page NOTE If the calibration is correctly initiated, the Start Calibration register will automatically reset to 0. If the instrument is unable to initiate the calibration (the instrument is in maintenance mode or already in calibration) the register will remain at 1 and the calibration will remain pending. Setting the Start Calibration register to 0 will remove any pending operation. 56

67 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor *Further Information On Registers Error Flags (Register 87 and 88) CHECKSUM ERROR 0x Eeprom checksum failure NOT USED 0x NOT USED OP0 FAULT 0x Op0 2 OPC FAULT 0x OpC 2 OP0 LIMITED 0x Op0 Op_0_Limit (default: 0.04) FAIL IN CAL 0x Motor jammed or manual abort MOTOR JAMMED 0x Either motor failed to park MEASURE LED FAIL 0x (Rm-R0) < 200 FLOOD LED FAIL 0x (Rf-R0) < 200 ADC OVERRANGE 0x Any MAX ADC signal > ADC FAULT 0x bit ADC failed to convert NOT USED 0x NOT USED FILTER BLOCKED 0x External signal BLOWER FAILED 0x External signal NEGATIVE OPACITY 0x Opacity < System Status (Register 104) 0 NORMAL 1 IN CAL CHECK 2 IN FACTORY CAL 3 MAINTENANCE 4 IN ALIGNMENT 5 IN MANUAL CAL System Operating Mode (Register 105) 0 NORMAL 3 MAINTENANCE 57

68 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual Calibration Status (Register 106) 0 PENDING 1 ZERO CHECK 2 ZERO TIMING 3 UPSCALE CHECK 4 UPSCALE TIMING 5 MOTOR CHECK 6 FINALISE 7 ABORTING CAL 8 START CAL CHECK 9 CALC CONSTANTS 10 NOT USED 11 SET BALANCE 12 EXTERNAL STANDARD 13 IN FACTORY CAL 14 IN CAL AUDIT 15 IN RECAL 16 WAITING CLOP 1 Output Units (Register 126) 0 OPTICAL DENSITY 1 OPACITY 2 DUST DENSITY 3 CONSTANT OUTPUT 4 CAL DRIFT 5 PLCF CLOP 2 Output Units (Register 149) As above Output Relays (Register 167) SYSTEM OK RELAY 0x SYSTEM FAIL 1 - SYSTEM OK SPAN CAL IN PROGRESS 0x DEACTIVATED 1 - ACTIVATED ZERO CAL IN PROGRESS 0x DEACTIVATED 1 - ACTIVATED ALARM1 RELAY 0x DEACTIVATED 1 - ACTIVATED ALARM2 RELAY 0x DEACTIVATED 1 ACTIVATED NOTE Other bits for internal use only 58

69 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Calibration Phases (Register 168) Three bits in this register are defined: all other bits are zero. If one bit is true then the others are false. Bit 0 Zero Phase True during a Calibration Check sequence. Goes true Cal Action Delay seconds before the zero reflector starts to drive in. Goes false before the upscale filter starts to drive in. Bit 1 Span Phase True during Calibration Check sequence. Goes true Cal Action Delay seconds before the upscale filter starts to drive in (ie simultaneously with Bit 0 going false) Goes false Cal Action Delay seconds before the zero reflector and upscale filter start to drive out. Bit 2 Audit Phase True throughout any Calibration Audit operation. Goes true Cal Action Delay seconds before the zero reflector starts to drive in. Goes false Cal Action Delay seconds before the zero reflector starts to drive out. Protocol Format The Model 4500 MkII + utilises the MODBUS RTU (Remote Terminal Unit) transmission format. Serial communications are fixed at 1 start bit, 8 data bits, no parity, 1 stop bit, and the data rate is fixed at 9600 baud. The following are examples of master query and slave response messages in RTU format, polling slave address 11 (hex). (03) Read Register(s) Query Response Slave Address 11 Slave Address 11 Function 03 Function 03 Register Address Hi 00 Byte Count 06 Register Address Lo 20 Data 1 Hi xx No. of Registers Hi 00 Data 1 Lo xx No. of Registers Lo 03 Data 2 Hi xx CRC Hi xx Data 2 Lo xx CRC Lo xx Data 3 Hi xx Data 3 Lo xx CRC Hi xx CRC Lo xx 59

70 Model 4500 MkII + Dust and Opacity MonitorInstallation and Maintenance Manual (06) Preset Register Query Response Slave Address 11 Slave Address 11 Function 06 Function 06 Register Address Hi 00 Register Address Hi 06 Register Address Lo 20 Register Address Lo xx Data Hi 00 Data Lo xx Data Lo 03 Data Hi xx CRC Hi xx CRC Hi xx CRC Lo xx CRC Lo xx (10 Hex) Preset Multiple Registers Query Response Slave Address 11 Slave Address 11 Function 10 Function 10 Register Address Hi 00 Register Address Hi 00 Register Address Lo 01 Register Address Lo 01 No. of Registers Hi 00 No. of Registers Hi 00 No. of Registers Lo 02 No. of Registers Lo 02 Byte Count 02 CRC Hi xx Data Hi xx CRC Lo xx Data Lo xx Data Hi xx Data Lo xx CRC Hi xx CRC Lo xx CRC Generation See MODBUS Manual. 60

71 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Error Codes The Model 4500 MkII + may return the following MODBUS exception codes. Code Exception Description 01 ILLEGAL FUNCTION The instrument only responds to codes 03, 06 and 10 (Hex). Any other function request will result in the return of this error. 02 ILLEGAL DATA ADDRESS Register number out of range. 03 ILLEGAL DATA VALUE Write request to a read-only register. 61

72 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B4 Periodic Modes of Operation B4-1 Calibration Check Transceiver 1. LED light source 7. Reference Detector 2. Flood LED 8. Concave Mirror 3. 50/50 Beam Splitter 9. Span Filter 4. Collimating Lens 10. Zero Point Reflector 5. Collimated Beam 11. Diffuser 6. Measurement Detector The transmissometer periodically performs a two step calibration check. In the first step, a zero-point reflector (10), mounted within the air purge of the Transceiver is placed into the optical axis. In the second step, the span filter (9) is also placed in the light path. The monitor reads the difference in light between the current zero point and the zero point established during the last clear stack calibration, and notes this value as the amount of drift and optical dust build-up. The opacity value of the span filter (9) is shown on the calibration certificate which accompanies the instrument. CAUTION Do not attempt to move the zero point reflector by hand. The precision gearbox will be irreparably damaged. See section B4-1 for identification. 62

73 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor B4-2 Calibration Audit A convenient Calibration Audit facility is provided, for carrying out the Calibration Audit tests required by USEPA and other Environmental Regulatory Authorities. Calibration Audit and Modbus Communications When the instrument is in maintenance mode Modbus communications are disabled. It is therefore not possible in this mode to monitor the results of the Calibration Audit and Response Time tests using the Modbus. If Modbus communications are required during a Calibration Audit, follow the instructions in Calibration Audit Method 2. Calibration Audit Method 1 (Modbus disabled) 1 Press and hold the Maintenance key unit the red LED illuminates (about 5 seconds). 2 Enter the password using the UP and DOWN arrow keys and then press Enter. The default password is Use the DOWN ARROW key to select Calibration and press ENTER. 4 Use the DOWN ARROW key to select CAL AUDIT and press ENTER Filter Slot 2 Zero Point Reflector CAUTION Do not attempt to move the zero point reflector (2). The precision gearbox will be irreparably damaged. 5 The zero reflector is driven into its working position. The displayed value should be 0.00 ± Note that this is fractional Opacity, i.e. 100 % is shown as Open the transceiver housing by releasing two quick-release clamps, and swing the instrument open on its hinges. 6 Insert a calibrated neutral density filter into slot 1. 7 Read and record the displayed opacity value. The instrument should read a value within ±1.0 % of the calibration filter. Note that this value will be corrected for the Optical Path length Ratio 63

74 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual (OPLR). If the OPLR is set to the default value of 0.5, then the displayed value should match the filter opacity. If the OPLR is not 0.5, then calculate the corrected value using the formula given below. 7 Remove the filter; insert, read and record the values for the other filters in turn as required by the procedure. 8 Remove the neutral density filter and close the transceiver. 9 The message ENTER when done is displayed. Press the ENTER key to complete the calibration audit. 1 Press the MAINTENANCE key for 2 seconds to exit maintenance mode. The red LED will go out. Modbus communications are the restored. Calibration Audit Method 2 (Modbus communications are maintained) 1 Press and hold the EXIT key for 5 seconds. 2 The zero reflector is driven into its working position. The displayed value should be 0.00 ± Note that this is fractional Opacity, i.e. 100 % is shown as Open the transceiver housing by releasing two quick-release clamps, and swing the instrument open on its hinges. 4 Insert a calibrated neutral density filter into slot 1. 5 Read and record the displayed opacity value. The instrument should read a value within ±1.0 % of the calibration filter. Note that this value will be corrected for the Optical Path length Ratio (OPLR). If the OPLR is set to the default value of 0.5, then the displayed value should match the filter opacity. If the OPLR is not 0.5, then calculate the corrected value using the formula given below. 6 Remove the filter, and insert, read and record the values for the other filters in turn as required by the procedure. 7 Remove the neutral density filter and close the transceiver. 8 Press and hold the Maintenance key unit the red LED illuminates (about 5 seconds.) 9 Press the MAINTENANCE key for 2 seconds to exit audit mode. The red LED will go out. OPLR correction formula Refer to section B2-4-3 for instructions on finding the OPLR for your instrument. Instrument Reading = 1- (1 - filter The filter opacity is given on the calibration certificate supplied with the calibration filter. 64 opacity) 1 OPLR

75 Operation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor B4.3 Re-calibration It is recommended that every three years a genuine clear stack calibration of the instrument is performed. The recalibration command is used in performing this operation. Re-calibration is also required if a calibration audit shows the instrument to be outside of acceptable limits. Please ensure that all optical surfaces are clean and the optical path is not obstructed before performing any calibration. Re-calibration must be carried out by a Land Instruments International Service Engineer or other competent person. If the flange to flange path length is altered (i.e. due to relocation of the instrument) contact Land Instruments International customer services for instrument pathlength setup advice. Re-calibration should be carried out under clear stack conditions or in a laboratory with the transceiver set to the correct flange-to-flange path length. If an automatic fail-safe shutter is used, you will need to ensure it stays open during the recalibration. To do this, disconnect the wires from the shutter to terminals 19 and 20 on the T-box and connect these wires together. Remember to re-connect the wires to the appropriate terminals after the recalibration is complete. 1 Press and hold the Maintenance key for 3 seconds until the red LED illuminates. 2 Enter the password using the or keys and then press Enter. The default password is Select the Calibration: menu with the or keys from the main menu. 4 Press the 'ENTER' () key. Scroll with the or keys until 'Re-calibrate' is displayed. 5 Press the 'ENTER' () key. The display will show 'Clear path'. Ensure the measuring path between the Transceiver and Retro-Reflector is clear of any obstruction. 6 When the measurement path is clear press the 'ENTER' () key again. The display will show 'Settling' while the clear path measurement is in progress, when complete the display will show '100% point'. 7 Block the beam ( if the instrument is mounted on the stack, then the simplest method for blocking the beam is to undo the two quick release clamps on the Transceiver and swing the unit open). 8 Press the ENTER () key when ready. The instrument will automatically continue and calculate the zero and span calibration check points. The display will indicate the progress of the re-calibration sequence. Once the re-calibration is complete, the Model 4500 MkII + will exit to the Re-calibration menu. 9 Unblock the beam on completion of the operation. 10 The Model 4500 MkII + is now correctly calibrated. The M203 Clear Stack Simulator option (if used) requires re-calibration immediately after re-calibration of the instrument. 11 Press and hold the Maintenance key for 1 second until the red LED switches off. The instrument is now is normal RUN mode. CAUTION Do not attempt to move the zero point reflector by hand. The precision gearbox will be irreparably damaged. Whenever the Land Instruments International Service Department is contacted regarding problems with an instrument, please have available information on the instrument type and serial number. This will enable the department to respond more accurately and efficiently. 65

76 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B4-4 Isokinetic Calibration The Model 4500 MkII + measures the opacity of dust and smoke emissions. As explained in the Reference manual, this value is related to the dust density in the stack, through the Beer-Lambert law (see section C1-2). In order to measure the dust density, it is necessary to know the Dust Gain (parameter 'k'), which relates optical density to dust density. Dust Gain is found by comparing with the measured Optical Density/Dust Density found by an isokinetically sampled dust measurement. The Model 4500 MkII + is designed to be easily calibrated relative to an isokinetic sample. Two methods may be used, depending on whether the instrument is to be calibrated relative to a single sample, or multiple samples. A single sample is simple to collect and analyse, but more often a series of measurements are taken under different load conditions or at different points across the diameter of the stack. This method gives a more accurate representation of the overall dust burden in the stack. 66

77 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Setting the Dust Gain value (single gravimetric value) The Model 4500 MkII + menu program contains a particularly simple method for calibrating the Dust Gain parameter against a single isokinetic sample. When preparations for doing an isokinetic sample are in place, press the Maintenance key for 3 seconds until the LED is illuminated. Enter the password using the or keys and then press Enter. The default password is 10. The system is unlocked and allows parameter access. 1. Select CALIBRATION: Isokinetic Cal: Acquire. 2. The display will show 'Start Isokinetic'. 3. Press 'ENTER' () key at the same time as the isokinetic sampling period is started. 4. The display will now show ' End Isokinetic'. 5. Press 'ENTER' () key at the end of the isokinetic sampling period. 6. The Model 4500 MkII display will show the average optical density value measured during the isokinetic sampling period. This value is stored in the memory of the Model 4500 MkII + until another isokinetic sampling sequence begins. 7. Press and hold the Maintenance key for 1 second to return to 'Run' mode. 8. When the isokinetic sample has been analysed, return to the User interface and select the Calibration: Isokinetic Cal: calculate function. Use the or keys to input the measured dust value, then press 'ENTER' () key. The Model 4500 MkII + will then calculate the Dust Gain value using the previously stored average optical density value. NOTE The method described above can also be applied to multiple isokinetic samples: Choose 'Start isokinetic' at the beginning of the first sample and 'End isokinetics' at the completion of the final sample. Once the samples have been analysed, calculate the mean dust value and input this into the Model 4500 MkII +. This is a less accurate method than that specifically for multiple isokinetic samples, which should be used in critical applications. 67

78 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Setting the Dust Gain value (multiple isokinetic samples) 1. When preparations for doing an isokinetic sample are in place, press the Maintenance key for 3 seconds until the LED is illuminated. Enter the password using the or keys and then press Enter. The default password is 10. The system is unlocked and allows parameter access. 2. Select the CALIBRATION: Isokinetic Cal: Acquire function. 3. The display will show 'Start Isokinetic'. 4. Press 'ENTER' () key at the same time as the isokinetic sampling period is started. 5. The display will now show ' End Isokinetic'. 6. Press 'ENTER' () key at the end of the isokinetic sampling period. The Model 4500 MkII + display will show the average optical density value, measured during the isokinetic sampling period. Average OD Write down the sample number and the average O.D. value. IMPORTANT A written record of all the O.D. values is essential. The Model 4500 MkII + will overwrite this value when the next sample is taken. 8. Repeat the sequence for each isokinetic sample. 68

79 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor When all the samples have been analysed gravimetrically, it will be possible to plot a graph of dust density against average optical density for each of the samples. Plot a 'best fit' straight line passing through the origin as shown below. The gradient of this line is the Dust Gain value for your application Isokinetic Dust Measurement MkII + Optical Dust Value Graph of Isokinetic Dust Measurement v 4500 MkII + Optical Density Value The Dust Gain value must now be input into the Model 4500 MkII + using the setup menu in the User interface. 1. Choose SETUP: Miscellaneous: Dust Gain. 2. Press 'ENTER' () key. Use the or keys to store. 3. Press and hold the Maintenance key for 1 second return to the 'Run' mode. The Model 4500 MkII + is now correctly calibrated for dust measurements. 69

80 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B4-5 M203 Clear Stack Simulator Checklist The M203 Clear Stack Simulator System (Part number ) contains the following: M203 Clear Stack Simulator Spare Apertures for M203 Simulator Spare Apertures for Dust Span Filter Spare Apertures for Dust Zero Reflector Hexagon Keys Hexagon Keys Spare Apertures for Dust Span Filter Spare Apertures for Dust Zero Reflector Unused Slot Spare Apertures for M203 Simulator M203 Clear Stack Simulator M203 Clear Stack Simulator System 70

81 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor The instrument serial number and pathlength are printed on the carry case label. It is important that the M203 is only used with the instrument it has been calibrated with. Please ensure the plant installation location (i.e. Stack 1) is written on the carry case label before placing the clear selfadhesive label (Provided by Land Instruments International) over the top of the carry case label for protection. M203 CLEAR STACK SIMULATOR M203 Carry Case Label 71

82 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Fitting the Simulator The M203 Clear Stack Simulator (Part Number ) is used during the Re-calibration routine when true clear stack conditions are unobtainable. The Simulator should be fitted, as described below, when 'Clear path' is displayed by the instrument (see Re-calibration). Follow the steps below, being careful NOT to move the sliding adjusting plate on the back of the Simulator. 1. The User interface display should read 'Clear path' (see Re-calibration). CALIBRATION Opacity: 0% Re-Calibrate: Opacity: 0% Clear Path 2. On the Transceiver undo the two quick release clamps and swing the unit open. 3. Remove the 5 crimp connectors from below the Automatic Zero Point Assembly. Make a note of the orientation of the wiring for reconnection. 5 Crimp Connectors CAUTION Do not attempt to ROTATE the zero point reflector by hand. The precision gearbox will be irreparably damaged. See section B4-1 for identification. 4. Undo the 2 socket head screws using the 5 mm hexagonal (Allen) key supplied and remove the Automatic Zero Point Assembly. Store in safe place until required for normal running of instrument. Continue to step 5. 72

83 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 5. Check that the serial number of the instrument corresponds to the number marked on the Simulator. 6. Offer up the Simulator and tighten the two 5mm Allen bolts as shown below. M5 Allen Bolt M5 Allen Bolt Sliding Adjusting Plate M203 Clear Stack Simulator 73

84 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual 7. On the User interface press the ENTER key and wait for the display to read '100% Point'. Opacity: 0% Clear Path Opacity: 0% 100% point 8. At the Transceiver undo the 2 socket head screws and remove the Simulator. Store the Simulator in the carry case provided until required for Re-calibration. 9. Offer up the Automatic Zero Point Assembly and tighten the 2 socket head screws. 10. Attach the 5 crimp connectors in the same orientation as previously noted. 11. The instrument is now ready to perform 100% point calibration. Opacity: 0% 100% point Opacity: 0% Re-cal complete 12. Always replace the Automatic Zero Point Assembly before pressing the ENTER key for 100% point calibration. The motor that lifts the reflector activates immediately after the 100% point calibration. IMPORTANT The instrument will display a fault if the Automatic Zero Point Assembly is not replaced before continuing with the 100% point calibration. M203 Clear Stack Simulator Carry Case 74

85 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor B4-6 M203 Clear Stack Simulator Calibration All instruments are shipped out from the factory configured to customers' requirements. Re-calibration of the M203 Clear Stack Simulator is required immediately after re-calibration of the instrument. It is recommended that re-calibration is performed every three years or if a Calibration Audit shows the instrument to be outside of acceptable limits. Please ensure that all optical surfaces are clean and the optical path is not obstructed before performing any calibration. If the flange to flange path length is altered (i.e. due to relocation of the instrument) contact Land Instruments International customer services for instrument pathlength setup advice. IMPORTANT Re-calibration should be carried out under clear stack conditions or in a laboratory with the Transceiver set to the correct flange-to-flange path length. The M203 Clear Stack Simulator should be re-calibrated following a genuine recalibration of the instrument only (recommended every three years). If in any doubt about these instructions, please contact Land Instruments International Customer Services Department before proceeding. Take care when handling the reflective surfaces as they can easily be scratched or made dirty. CAUTION Do not attempt to ROTATE the zero point reflector by hand. The precision gearbox will be irreparably damaged. See section B4-1 for identification. Immediately after a genuine clear stack re-calibration perform the following steps for re-calibration of the M203 Clear Stack Simulator. 1 Press the Maintenance key for 3 seconds until the LED is illuminated. The system is unlocked and allows parameter access. 2 Enter the password using the or keys and then press Enter. The default password is Undo the two quick release clamps on the Transceiver, swing open the case and identify the Automatic Zero Point Assembly Continue to step 3. 75

86 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Automatic Zero Point Assembly 3 Remove the Automatic Zero Point Assembly by undoing the two socket head screws. 4 Fit the M203 Clear Stack Simulator as described in the previous section. 5 At the User interface set the instrument to display negative values (see section C4-4) and then observe the measurement reading with the M203 Clear Stack Simulator still attached. 6 Loosen the locking nut on the sliding adjusting plate and slide the plate until the instrument is measuring zero. If the instrument cannot be set to measure zero opacity by adjusting the sliding adjuster on the back of the M203 Simulator it is necessary to change the aperture and grating that cover the reflective surface. Select an aperture plate and grating using the table in Appendix A-1. Identify the B value corresponding to the aperture plate and grating in use (i.e. Aperture Plate D, Grating 2 corresponding B value 0.94). If the black wedge shape on the front of the sliding adjuster on the M203 Simulator completely covers the reflective surface then replace the current aperture plate and grating with the ones corresponding to the next highest B value (i.e. Next highest B value 0.97 corresponding aperture plate C and grating 2). If the black wedge shape on the front of the sliding adjuster on the M203 Simulator cannot be seen then replace the current aperture plate and grating with the ones corresponding to the next lowest B value (i.e. Next lowest B value 0.91 corresponding aperture plate E and grating 2). Continue to step 7. 76

87 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 7 Lock the sliding adjusting plate in place. IMPORTANT The M203 Clear Stack Simulator once calibrated to an instrument should not be adjusted unless undergoing another re-calibration. 8. Undo the 2 socket head screws and remove the Simulator. Store the Simulator in the carry case provided until required for Re-calibration. 9. Offer up the Automatic Zero Point Assembly and tighten the 2 socket head screws (5mm). 10. Attach the 5 crimp connectors in the same orientation as previously noted. 11. Close the Transceiver casing and press the Maintenance key for 1 second until the LED switches off. The instrument is now in RUN mode. The instrument is now ready for normal operation. 77

88 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B4-7 Zero Point Reflector Adjustment All instruments are shipped out from the factory configured to customers' requirements. The following procedures should only be necessary if the optical path length or the opacity standard has been changed. If in any doubt about these instructions, please contact Land Instruments International Customer Services Department before proceeding. Take care when handling the reflective surfaces as they can easily be scratched or made dirty. CAUTION Do not attempt to ROTATE the zero point reflector by hand. The precision gearbox will be irreparably damaged. See section B4-1 for identification. 1. Remove the instrument from the stack and set up on test stands positioned at the correct flange to flange distance. 2. Press the Maintenance key for 3 seconds until the LED is illuminated. The system is unlocked and allows parameter access. 3. Perform a Re-calibration (see section B4-3). 4. Display and make note of the 'B' value on the Parameters menu (see section B2-4). 5. On the table in Appendix A find the 'B' value (or the nearest lower value). The value may occur in two columns. Select the Aperture Plate (horizontally) and the Grating (vertically) relating to the 'B' value. 6. Install the selected Aperture Plate and Grating as described in this section. Continue to step 7. 78

89 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 7. Repeat the Re-calibration procedure (see section B4-3). 8. Display the parameter 'B' on the Parameters menu (see section B2-4). 9. The 'B' value should now be within the range 0.95 to The zero point reflector is ready for normal use. If the 'B' value is not within the range 0.95 to 1.05 then it will be necessary to change the aperture and grating as described below. If the 'B' value is less than 0.95 use the Aperture Plate below the previously selected aperture plate in the table. If the 'B' value is greater than 1.05 use the Aperture Plate above the previously selected aperture plate in the table. 10. Repeat the Re-calibration as before and check the 'B' value again. Repeat steps 6 to 10 if required. 79

90 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Zero Point Reflector, Aperture Plate and Grating Installation A range of apertures and gratings for the Zero Point Reflector are provided with the instrument. CAUTION Do not attempt to ROTATE the zero point reflector by hand. The precision gearbox will be irreparably damaged. See section B4-1 for identification. Removing the Zero Point Reflector Key. 2 Zero Point Reflector 1. Zero Point Reflector 2. 2 M3 Allen head screws 3. Automatic Zero Point Assembly 1. Undo the two quick release clamps on the Transceiver and swing the unit open, revealing the Automatic Zero Point Assembly. 2. Undo the 2 M3 socket head screws (2) (as illustrated above) holding the Zero Point Reflector in place and remove it from the Automatic Zero Point Assembly using a 2.5mm Allen Key. 3. To replace, reverse the procedure. 80

91 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Installing an Aperture Plate and Grating Zero Point Reflector Variable Aperture Assembly Key. 1. Zero Point Reflector Holder 2. Grating 3. Aperture Plate 4. Reflector Plate 5. 3mm Allen head screws 1. Undo the 3 M3 socket head screws (5) using a 2.5mm hexagonal (Allen) key and remove the Reflector Plate, Aperture Plate and Grating. 2. Identify the selected Aperture Plate and Grating as shown above. 3. Set the Aperture and Grating Plates into the recess, ensuring that the tabs on both are aligned with the slot on the holder. 4. Locate the Reflector Plate and tighten the 3 socket head screws. 5. Refit the Zero Point Reflector on to the Automatic Zero Point Assembly as described previously. 81

92 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual B4-8 Upscale Span Filter Adjustment U.S. Legislation requires that the instrument is periodically checked using an Upscale Calibration Value that is 150% to 190% of the applicable opacity standard. This is achieved using an Automatic Span Filter. A range of gratings for the Span Filter are provided with nominal Opacities of 5%, 10%, 15%, 20%, 28%, 36%, and 45%. The instrument is factory set with a span filter of 28%. To install an alternative filter from the set provided, follow the procedure outlined below. Removing the Span Filter 1. Ensure that the power to the instrument is switched off. 2. Undo the two quick release clamps on the Transceiver and swing the unit open, revealing the Automatic Zero Point Assembly. 3. Undo the hinge pins (captive in the purge assembly) using a 5mm Allen key and lift the Transceiver away from the purge assembly. 4. Undo the sixteen M4 socket head screws holding the outer casing in place using a 3mm hexagonal (Allen) key and partly withdraw the casing. NOTE A Static protection wrist band should be worn at this point 5. Disconnect the Umbilical Klippon terminal strip and remove the outer casing. Continue to step 6. 82

93 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor 6. Undo the 2 flat head screws (accessible from underneath the Transceiver) holding the Micro Processor Board in place (NOTE:- These screws are captive). 7. Disconnect the Klippon terminal strip connecting the Micro Board to the Main P.C.B. 8. Remove the Micro Processor Board. CAUTION Do not attempt to ROTATE the span filter by hand. The precision gearbox will be irreparably damaged. See section B4-1 for identification. 1 Key. 2 Span Filter Assembly 1. Span Filter 2. 2 Allen head screws (3mm) 9. Undo the 2 M3 socket head screws (2) holding the Span Filter in place as shown above and remove it. 10. To replace, reverse the procedure. 83

94 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Installing a Grating Span Filter Key. 1. Span Filter Holder 2. Grating 3. M3 Allen head screws 1. Undo the 3 M3 socket head screws (3) using a 2.5mm socket (Allen) Key and remove the old grating. 2. Locate the new grating (see the Span Filter Gratings table in Appendix A). 3. Refit the new grating using the 3 M3 socket head screws. 4. Locate the Span Filter onto the instrument as described previously. 84

95 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor C1 Theory of Operation and Application C1-1 General Outline When a beam of light crosses a medium containing smoke or dust particles, some of the light is transmitted and some is lost due to scattering. The fraction which is transmitted is called the transmittance and the fraction which is lost is the opacity. In the early days of emissions measurement, the opacity of the smoke leaving a stack was measured by the Ringelmann method in which a trained observer makes a visual estimate of its appearance. Modern methods for opacity measurement are far more sophisticated than the Ringelmann method, but many of the specifications relate back to the way the human eye sees smoke emissions. The wavelength response of an opacity monitor must mimic that of the human eye. An instrument must have a nearly photopic response. The Land Model 4500 MkII + uses a high-intensity green LED light source to achieve this. 85

96 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual C1-2 Beer-Lambert s Law The mathematical relationship between the light transmitted by a medium and the quantity of pollutant present is known as the Beer-Lambert Law and may be written; τ = I = e -acl I o where: τ = Transmittance I o = Intensity of light into the medium (see 1 below) I = Intensity of light out of the medium (see 3 below) a = Attenuation Coefficient c = Concentration of Pollutant L = Distance light beam travels through the medium (see 2 below) Since opacity (Op) = 1 - τ, the above equation becomes: (1 - Op) = e -acl or Op = 1 - e -acl Note that the quantity c is the amount of dust in the optical path. Optical Density (or extinction) is defined as; OD = -log 10 τ = -acl/2.303 c = k x OD where k = al By comparing a series of optical density measurements with gravimetric dust measurements taken at the same time, it is possible to determine the value of k. 86

97 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor C1-3 Optical Pathlength Ratio (OPLR) The last item that we need to address is the fact that opacity monitors may not always be mounted at the exit of a stack. Since the Ringelmann observer always views opacity at the exit of a stack, we must also introduce a factor to correct for the change in pathlengths between the measurement and exit diameters of the stack. It should also be pointed out at this time that the Land Model 4500 MkII + Dust & Opacity Monitor is a double pass instrument. This means that the light beam crosses the medium twice and hence experiences twice the amount of absorption as illustrated below. This must also be corrected in our system. The Optical Path Length Ratio (OPLR) is the ratio between the diameter of the stack exit and the distance travelled through the stack gases by the beam. For a double-pass instrument like the Model 4500 MkII, the OPLR is equal to half the PLCF i.e. The Path Length Correction Factor (PLCF) is only relevant for Opacity measurements. It is the ratio between the diameter of the stack exit and the diameter of the stack at the point where the instrument is installed. For a parallel stack, the PLCF is 1.0. For a tapering stack which is narrower at the exit than the base, the PLCF is less than 1.0. OPLR = PLCF 2 The parameter used in the Model 4500 MkII + is the OPLR, and it has a default value of 0.5, corresponding to a parallel sided duct. In early instruments, this parameter is labelled as PLCF Key 1. Light source l o 4. Reflector 2. Detector 5. Beam Splitter 3. Distance light beam passes through medium (L) Double Pass System 87

98 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual We can use the previous equations to calculate the opacity at the stack exit, if we define the pathlength correction factor (PLCF); PLCF = L e L m where: L e = the exit pathlength L m = the measurement pathlength OPLR = PLCF 2 Op e = OD OPLR 88

99 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor C1-4 Examples of Different Optical Path Length Correction Ratios (OPLR) Straight stack. Measurement pathlength and exit pathlength are equal. PLCF = 1.00, OPLR = 0.50 Example 1 Straight stack, monitor on narrow duct. Measurement pathlength is less than exit pathlength. PLCF > 1.00, OPLR >0.50 Example 2 Stack narrows towards exit. Measurement pathlength is greater than exit pathlength. PLCF < 1.00, OPLR <0.5 Example 3 89

100 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual C2 Requirements for Environmental Legislation The Model 4500 MkII + meets or exceeds the requirements of U.S. 40CR60 AppB PS1 and ASTM Standard Practice D6216. It has been approved be TÜV Rhineland in Germany for installations under 13th BImSch V and TA Luft, Report N o 936/808016/A. 90

101 Installation and Maintenance Manual Model 4500 MkI I+ Dust and Opacity Monitor C3 Physical Principles C3-1 General Description The Land Instruments International Model 4500 MkII + Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam through flue gases. An internal microprocessor calculates opacity, dust density and other parameters. The instrument comprises the following parts: The Transceiver which contains all of the optical and electro optic components; the Retro-Reflector containing a plastic or glass retro-reflector; the Termination Box where the customer terminations are located; and the air purge system. An optional data display Control Room Unit is available. The air purge system can take several forms depending upon individual site requirements. Single and dual electric blowers are available, as are compressed-air driven devices. Continuous purge air supply is essential to prevent dust and corrosive gases from affecting the optical system. Automatic fail safe shutters can also be fitted for temporary protection in the event of a purge air failure. The entire system is designed for continuous operation in all weather conditions, with minimal maintenance. Retro-Reflector Termination Box Transceiver 91

102 Model 4500 MkI I+ Dust and Opacity Monitor C3-2 Principle of Operation Installation and Maintenance Manual The Land Model 4500 MkII + is intended to be the most accurate and reliable opacity monitor available. It uses a high-intensity green LED source, very low noise electronics and a sophisticated normalisation system to minimise calibration drift. The LED is electronically modulated at a frequency of 3kHz in order to reduce noise and eliminate errors due to background light. Electronic modulation eliminates the need for a mechanical chopper and so the only moving parts are the motors used in the calibration system. These motors have a very low duty cycle and are very reliable Transmissometer 1. LED light source 7. Reference Detector 2. Flood LED 8. Concave Mirror 3. 50/50 Beam Splitter 9. Span Filter 4. Collimating Lens 10. Zero Point Reflector 5. Collimated Beam 11. Diffuser 6. Measurement Detector The Transceiver is illustrated above. Light from source LED1 (1) passes through the diffuser (12) and on to the 50/50 beamsplitter (3). The transmitted portion passes on to the lens (4) which projects a well-defined, collimated beam (5) across the measuring path to the distant Retro-Reflector. Light returned from the retro is focused by the lens (4) onto measurement detector (6). The portion of light originally reflected by the beamsplitter (3) falls on the concave mirror (8) which focuses it onto reference detector (7). The opacity value can be calculated from the ratio of the signals on the two detectors. This is true only as long as long as the responsivity of the detectors (6 and 7) and the gain of their associated electronics remains constant. In practice, temperature variations and ageing of the components means that 92

103 Installation and Maintenance Manual Model 4500 MkI I+ Dust and Opacity Monitor this cannot be guaranteed. The Model 4500 MkII + uses a novel method to compensate for such changes by using the flood LED (2) to flood both detectors (6 and 7) with light. Because it uses no focusing optics, there is no possibility of misalignment and so any relative change in sensitivity between detectors (6 and 7) will lead to a change in the ratio of signals from LED2 (2). By alternating light sources (1) and (2) once every second, the normalisation procedure is effectively continuous. The microprocessor performs the calculations required to perform the normalisation and to convert the opacity measurement into optical density or dust density as required. Calibration Check The transmissometer periodically performs a two step calibration check. In the first step, a zero-point reflector (10), mounted on the outside of the Transceiver is placed into the optical beam. In the second step, the span filter (9) is also placed in the light path. The monitor reads the difference in light level between the current value and that established during the last clear stack calibration, and makes a correction. The opacity value of the span filter (9) is shown on the calibration certificate which accompanies the instrument. 93

104 Model 4500 MkI I+ Dust and Opacity Monitor Installation and Maintenance Manual C4 User Interface C4-1 Operational Structure The operational structure of the Model 4500 MkII + is basically made up of a menu spine containing five menus FAULTS, CALIBRATION, SETUP, DISPLAY and PARAMETERS. Scroll through the menu spine using the and keys, once a menu has been selected press the ENTER () key to access it. For the navigation purposes of this manual, wherever an asterisk (*) is shown press the ENTER () to access a further sub-menu. Pressing EXIT returns the user to the previous menu. Operation of the instrument should be carried out by an authorised, competent person only. Enter the password using the arrow keys and press Enter. The default password is 10. The menus available are explained in more detail in the this section. FAULTS CALIBRATION SETUP DISPLAY PARAMETERS eg Faults: 0 or Faults: xx Fail in Cal Cal Check Re-Calibrate* Isokinetic Cal* Cal Audit* Manual Cal* Recall Factory* Cal Setup* Outputs* Alarms* Miscellaneous* Service Overview of Operational Structure All menus marked * use a further sub-menu. Top line* Bottom line* SO Zero Damper: xx.xx Sf Flood Sm Damper: xx.xx Ro Measure Damper: xx.xx Rf Cal Damper: Rm xx.xx C OP1 Damper: X xx.xx B OP2 Damper: xx.xx G PLCF: xx.xx Q Last Cal: xx.xx Dust Gain: xx.xx Zero Comp: xx.xx Dust Offset: xx.xx Isokinetic OD: xx.xx Version: xx.xx 94

105 Installation and Maintenance Manual C4-2 Faults Screens Model 4500 MkI I+ Dust and Opacity Monitor FAULTS Opacity: 0% Faults: 0 or Opacity: 0% Faults: 1 Opacity: 0% Faults: Fail in cal FAULTS On selection of FAULTS from the menu spine, press the ENTER () key. No Faults Detected If no faults are detected by the software, the display will show ' Fault: 0' and the user may return to the menu spine by pressing the EXIT key. Faults Detected However, if a fault or faults are detected then the display will show 'Faults: xx' the xx denoting the number of faults detected. Press the ENTER () key again to display a description of the fault/ faults. See the Fault Finding section in this manual. The user may then return to the menu spine by pressing the EXIT key. 95

106 Model 4500 MkI I+ Dust and Opacity Monitor C4-3 Calibration Screens Installation and Maintenance Manual The instrument is checked and calibrated using the calibration menu. On selection of CALIBRATION on the menu spine, press the ENTER' () key. The calibration menu contains seven sub menus: Calibration Check Re-Calibration Isokinetic Calibration Calibration Audit Manual Calibration Recall Factory Calibration Setup Illustrated below is the operational structure for the Calibration menu. Each sub-menu found within the Calibration menu is explained in more detail within this section. (A Zero and Span Check is carried out taking approximately 3 minutes) CALIBRATION Clear Path Settling Clear Path OK 100% point Settling 100% Opacity OK Running in Zero Balance OK Running in Span Settling Running out Re-cal complete Cal Check Re-Calibrate Isokinetic Cal Cal Audit Manual Cal Recall Factory Cal Setup Acquire Calculate Start Isokinetic End Isokinetic Isokinetic O.D. Meas. Dust x.xx Meas. Dust o.o to Running in When Done Running out C: xxxx x: x.xxx Running in B: x.xxx Running out B Restore Factory YES Factory Values Interval x.xxh Time to next cal. xxh xmins Interval x.xxh Time to next cal. Time to next cal. xxh xmins xxh xmins 96

107 Installation and Maintenance Manual Opacity: 0% Cal. Check: CALIBRATION CHECK (CAL CHECK) Model 4500 MkI I+ Dust and Opacity Monitor On selection press the ENTER' () key. The monitors will perform a zero and span check. This will take approximately three minutes to complete. During the first half of this period a zero point reflector is automatically placed into the sight path of the system. During the second half of this period the zero point reflector remains in place and a span filter is automatically placed before it into the sight path. Opacity: 0% Re-Calibrate: Opacity: 0% Clear Path Opacity: 0% 100% point Opacity: 0% Re-cal complete RE-CALIBRATE On selection of Re-Calibrate press the ENTER' () key to initiate the recalibration sequence. This sequence is easily followed via the sub-menu described below. (Clear Stack Calibration) This menu provides a clear stack calibration sequence. On selection press the ENTER () key. The display will show 'Clear path'. Ensure the that no obstruction, dust, gases are present in the sight path that would effect a zero opacity condition. When the clear stack conditions are satisfactory, press the ENTER () key to continue. 100% Point Calibration The next sequences follow automatically until '100% point' is displayed. This is a request for a 100% opacity condition to be set up. The simplest way to achieve this is to unclip the Transceiver case and swing it open. This breaks the line of sight path to the Retro-Reflector and creates an 100% opacity condition. When ready, press the ENTER' () key. The rest of the sequence follows automatically until the display shows 'Re-cal complete'. 97

108 Model 4500 MkI I+ Dust and Opacity Monitor Opacity: 0% Isokinetic Cal Acquire Calculate ISOKINETIC CALIBRATION Installation and Maintenance Manual This procedure is done in conjunction with an isokinetic sample or samples, being taken at the same time and under the same conditions as the measurements being taken by the Model 4500 MkII +. On selection press the ENTER () key. Two further sub-menus are available Acquire and Calculate. Select the required sub-menu using the and keys. Isokinetic Cal Acquire: Isokinetic Cal Start Isokinetic Isokinetic Cal End Isokinetic Isokinetic Cal Isokinetic O.D.: x.xx Acquire (Isokinetic Calibration sub-menu) From the Isokinetic Calibration sub-menu press the ENTER' () key, as previously described, to display 'Acquire'. This screen allows access to the acquisition mode. Press the ENTER () key again and thereafter the next two steps. The user can follow the subsequent, self explanatory start/stop displays to be timed to occur instantaneously with the isokinetic sampling. Finally the display shows the Average O.D. (Optical Density) value read by Model 4500 MkII +, this is automatically stored by the instrument. (Wait for isokinetic sample results). 98

109 Installation and Maintenance Manual Isokinetic Cal Calculate: Isokinetic Cal Meas. Dust: x.xx Model 4500 MkI I+ Dust and Opacity Monitor Calculate (Isokinetic Calibration sub-menu) Using the or keys when 'Acquire' is displayed to access the Calculate sub-menu. Press the ENTER' () key to select 'Meas. Dust x.xx (notice the underlined character) and enter the isometric dust value (when available) using the and keys, provided by the isokinetic sampling. For multiple isokinetic samples repeat the single sample sequence for the number of required times and record the results. Draw a graph from the readings. For details see the section on Dust Calibration methods. Opacity 0% Cal. Audit Cal. Audit Done Opacity 0% Cal. Audit CALIBRATION AUDIT (CAL AUDIT) This sequence is provided so that verification by an independent check using external audit filters can be carried out. On selection of Cal. Audit press the ENTER' () key to insert the zero reflector. The words Running in are displayed briefly. Press the ENTER' () key when the word done' is displayed. The words Running out will be displayed briefly. Press the ENTER' () key. to end the 'Cal Audit' sequence. Press the EXIT key to return to the Calibration menu. 99

110 Model 4500 MkI I+ Dust and Opacity Monitor Opacity 0% Manual Cal. MANUAL CALIBRATION (MANUAL CAL) Installation and Maintenance Manual This sequence is not recommended to be followed by the user. The manual cal sequence requires values to be entered manually. Re-calibrate is a more accurate operation. This provision is of more practical use to a service engineer. Opacity 0% Recall Factory Opacity 0% Restore Factory Opacity 0% Restore Factory: No Opacity 0% Restore Factory: Yes FACTORY SETTINGS (RECALL FACTORY) Provides a simple method to return the Model 4500 MkII + to its factory calibration state. This may be helpful e.g. where a re-calibrate sequence has not been successful. On selection of Recall Factory from the Calibration menu press the ENTER' () key. The display reads Restore Factory, press the ENTER' () key again and then select YES or NO using the or key. Press the ENTER' () key whilst YES is displayed to return the instrument back to its factory settings. Press the ENTER' () key whilst NO is displayed to return to the Recall Factory screen on the Calibration menu. Opacity 0% Factory Values Opacity 0% Cal. Setup Interval Time to next cal. CALIBRATION SETUP (CAL SETUP) On selection of the Cal. Setup sub-menu press the ENTER () key. To set the time interval between calibrations (Interval x.xxh) and the time that the instrument will wait before performing the first calibration (Time to next cal). These two options appear as a sub-menu and are scrolled by pressing the or keys. 100

111 Installation and Maintenance Manual Cal. Setup Interval: Cal. Setup Interval: Cal. Setup Interval: 24h 24h 5h Interval Model 4500 MkI I+ Dust and Opacity Monitor On selection of Interval x.xxh press the ENTER' () key (notice the underlined x ). Use the and keys to select the time interval (in hours) between automatic calibrations. The default setting is 24 hours. Once a time interval has been selected it is set by pressing the EXIT key which returns the display to the Cal Setup screen. NOTE If 0 (zero) is entered for the cal interval, the internal automatic calibration facility is disabled. Calibration check sequences can be initiated by placing a contact closure across terminal 36 and 37 inside the Termination Box or via Modbus. Time to next cal. xxh xxmins Time to next cal. xx h xx mins Time to next cal. 2 h xx mins Time to Next Calibration On selection of Time to next cal press the ENTER' () key (notice the underlined x next to the h on the bottom line). The time interval before the first calibration can now be set. First select the hours using the and keys and then press ENTER' () (notice the underlined x has moved under character next to mins ). Use the and keys again to select the minutes required. Once a time interval has been selected it is set by pressing the ENTER' () key. Press the EXIT key to return the display to the Cal Setup screen. Time to next cal. 2 h 10 mins 101

112 Model 4500 MkI I+ Dust and Opacity Monitor C4-4 Setup Screens Installation and Maintenance Manual The instrument is made ready for operation using the Setup menu. On selection of Setup on the menu spine press the ENTER' () key. The setup menu contains four sub-menus: Outputs Alarms Miscellaneous Service Illustrated below is the operational structure for the Calibration menu. Each sub-menu found within the Calibration menu is explained in more detail within this section. SETUP Output 1* Averaging 1* Output 2* Averaging 2* Outputs Alarms Miscellaneous Service Alarm 1 Alarm 2 AL1 Type*: O.D. AL1 Trip*: 0.00 Delay*: 5s AL1 Type*: O.D. AL1 Trip*: 0.00 Delay*: 5s Align* Opac. disp*: % O/P1 Range*: 4-20 O/P2 Range*: 4-20 Dust Gain*: x Dust Offset*: x OP0 Limit* Station number*: x Link*: Not fitted Display -ve: No Entry Code: xx All menus marked * use further sub-menus. 102

113 Installation and Maintenance Manual Setup Output Screens (Outputs) Model 4500 MkI I+ Dust and Opacity Monitor Two signal outputs are available to the user and are setup using the Output 1 and Output 2 submenus respectively. The time period used for block averaging may be set independently for each output using the Average 1 and Average 2 sub-menus. Illustrated below is the operational structure for the Output 1 and Averaging 1 sub-menus. The operational structure for Output 2 and Averaging 2 are identical. Both Output 1 and Averaging 1 sub-menus are explained in more detail within this section. SETUP Outputs Alarms* Miscellaneous* Service* Output 1 Averaging 1 Output 2* Averaging 2* Averaging: Off xh xm xs Averaging: Off xh xm xs Opacity Range: x.x During Cal.:Track Averaging: On xh xm xs Averaging: On xh xm xs Averaging: On xh xm xs Opacity Dust Constant Current Cal. Drift Optical Density Dust Range: x.x During Cal.:Track Constant Current Const. Current:x.x During Cal.:Track Cal. Drift Range: x.x During Cal.:Track Optical Density Range: x.x During Cal.:Track 103

114 Model 4500 MkI I+ Dust and Opacity Monitor Outputs Output 1 SETUP OUTPUTS (OUTPUT 1) Installation and Maintenance Manual The first customer output is set from this menu. On selection press the ENTER' () key. There are now two further options to set for each of the following (gain access as described in the earlier in this section): Opacity, Dust, Constant Current, Calibration Drift, Optical Density. Output 1 Opacity Output 1 Range: x.x Opacity On selecting Opacity press the ENTER' () key (notice no underlining). Two options are available, Range (Opacity range is in fractional opacity; i.e. 0.5 is 50% opacity) and During Cal. These two options are scrolled by pressing the and keys and can be selected by pressing the ENTER' () key to reveal an underlined character. Range of Output 1 (Range) Output 1 Range: x.x On selecting Range x.x press the ENTER' () key as described in Opacity above until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to Range x.x (no underlined characters) as illustrated. Output 1 Range: Output 1 During Cal.: Output 1 During Cal.: Output 1 During Cal.: x.x Track Track Hold Track or Hold output during calibration (During Cal) On selecting the During Cal: Track display, press the ENTER' () key as previously described in Opacity, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to During Cal: Track or During Cal: Hold (no underlined characters) as illustrated. Press the EXIT key to return the display to Output 1 104

115 Installation and Maintenance Manual Output 1 Dust Output 1 Range: x.x Dust. Model 4500 MkI I+ Dust and Opacity Monitor On selecting Dust press the ENTER' () key (notice no underlining). Two options are available, Range (Dust range is in mg/m 3 ) and During Cal. These two options are scrolled by pressing the and keys and can be selected by pressing the ENTER' () key to reveal an underlined character. Output 1 Range: Output 1 Range: Output 1 During Cal.: Output 1 During Cal.: Output 1 During Cal.: x.x x.x Track Track Hold Range of Output 1 (Range) On selecting Range x.x press the ENTER' () key as described in Dust above, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to Range x.x (no underlined characters) as illustrated. Track or Hold output during calibration (During Cal) On selecting During Cal: Track press the ENTER' () key as described in Opacity above, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to During Cal: Track or During Cal: Hold (no underlined characters) as illustrated. Press the EXIT key to return the display to Output 1 105

116 Model 4500 MkI I+ Dust and Opacity Monitor Output 1 Output 1 Output 1 Constant Current Output 1 Constant : Output 1 Constant Current x.xma Constant Current Installation and Maintenance Manual Constant Current is normally used to calibrate the users data acquisition system. On selecting Constant press the ENTER' () key (notice no underlining). Two options are available, Constant Current and During Cal. These two options are scrolled by pressing the and keys and can be selected by pressing the ENTER' () key to reveal an underlined character. Constant On selecting Constant press the ENTER' () key as described in Constant Current above, the display changes to Constant x.xma (notice the underlined character. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to Constant x.x (no underlined characters) as illustrated. Press the EXIT key to return the display to Output 1 Output 1 During Cal.: Track Output 1 During Cal.: Track Output 1 During Cal.: Hold 106

117 Installation and Maintenance Manual Output 1 Cal. Drift Output 1 Range: x.x Calibration Drift (Cal. Drift) Model 4500 MkI I+ Dust and Opacity Monitor On selecting Cal. Drift press the ENTER' () key (notice no underlining). Two options are available, Range and During Cal. These two options are scrolled by pressing the and keys and can be selected by pressing the ENTER' () key to reveal an underlined character. Cal. Drift displays any drift that may occur between calibrations. Range of Output 1 (Range) Output 1 Range: x.x On selecting Range x.x press the ENTER' () key as described in Calibration Drift above, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to Range x.x (no underlined characters) as illustrated. Output 1 Range: Output 1 During Cal.: Output 1 During Cal.: Output 1 During Cal.: x.x Track Track Hold Track or Hold output during calibration (During Cal) On selecting During Cal: Track press the ENTER' () key as described in Calibration Drift above, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to During Cal: Track or During Cal: Hold (no underlined characters) as illustrated. Press the EXIT key to return the display to Output 1 107

118 Model 4500 MkI I+ Dust and Opacity Monitor Output 1 O.D. Output 1 Range: x.x Optical Density (O.D.) Installation and Maintenance Manual On selecting O.D. press the ENTER' () key (notice no underlining). Two options are available, Range (O.D. range is in units of Optical Density) and During Cal. These two options are scrolled by pressing the and keys and can be selected by pressing the ENTER' () key to reveal an underlined character. Output 1 Range: Output 1 Range: Output 1 During Cal.: Output 1 During Cal.: Output 1 During Cal.: x.x x.x Track Track Hold Range of Output 1 (Range) On selecting Range x.x press the ENTER' () key as described in O.D. above, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to Range x.x (no underlined characters) as illustrated. Track or Hold output during calibration (During Cal) On selecting During Cal: Track press the ENTER' () key as described in O.D. above, until an underlined character appears. Select the required value by pressing the and keys. Press the ENTER' () key again to return the display to During Cal: Track or During Cal: Hold (no underlined characters) as illustrated. Press the EXIT key to return the display to Output 1 108

119 Installation and Maintenance Manual Outputs Output 1 SETUP OUTPUTS (AVERAGING 1) Model 4500 MkI I+ Dust and Opacity Monitor On selection of Averaging 1 from the Output 1 menu, as described previously, press the ENTER' () key. The display changes to Averaging: Off on the top line and the averaging time intervals are displayed on the bottom line. The averaging option sets the time interval at which the outputs will be made. It is possible to switch the averaging option on or off and to alter the time interval required. Averaging: Off xh xm xs Averaging: Off xh xm xs Averaging: Off xh xm xs Averaging: Off xh xm xs Averaging: Off xh xm xs Altering the Averaging Settings Before altering the averaging settings, make sure the O is underlined and then press the ENTER' () key. Set the averaging to On or Off as appropriate by pressing the or keys and then press the ENTER' () key to alter the time interval. Press the and keys to select an appropriate number of hours and then press the ENTER' () key. Continue using the and keys to select appropriate values for the minutes and seconds. Each time press the ENTER' () key to move between hours, minutes and seconds. Press the EXIT key to return to the Averaging 1 display. SETUP OUTPUTS (OUTPUT 2) The settings for signal output 2 are identical to signal output 1. Press the and keys to scroll through this sub menu until Output 2 is displayed, then press the ENTER () key as for Output 1 previously described. SETUP OUTPUTS (AVERAGING 2) The settings for averaging the second signal output are identical to that for signal output 1. Press the and keys to scroll through this sub menu until Averaging 2 is displayed, then press the ENTER () key as for Averaging 1 previously described. 109

120 Model 4500 MkI I+ Dust and Opacity Monitor Setup Alarms (Alarms) Installation and Maintenance Manual Two alarm facilities are available to the user, each may be programmed to trip at specified levels with a 0 to 30 seconds delay for Optical Density, Opacity or Dust as illustrated below. SETUP AL1 Type: O.D. AL1 Trip: 0.00 Delay: 5s Outputs* Alarms Miscellaneous* Service* Alarm 1 Alarm 2 AL1 type: O.D. AL1 trip: 0.00 Delay: 5s AL2 Type: O.D. AL2 Trip: 0.00 Delay: 5s AL2 type: O.D. AL2 trip: 0.00 Delay: 5s 110

121 Installation and Maintenance Manual SETUP Alarms Alarms Alarm1 Alarms AL1 type: Alarms AL1 type: O.D. O.D. Alarms AL1 trip: 0.00 Alarms AL1 trip: 0.00 Alarms Delay: Alarms Delay: 5s 5s SETUP ALARMS (ALARMS) Model 4500 MkI I+ Dust and Opacity Monitor On selecting Alarms press the ENTER' () key and Alarm 1 is displayed. Press the or keys to scroll through the two alarm facilities. SETUP ALARMS (ALARM 1) From the Alarm 1 display press the ENTER' () key to access 'AL1 type: O.D.'. It is now possible to scroll through three options type, trip and delay by pressing the and keys. Alarm 1 Type (AL1 type) On selection of AL1 type: O.D. press the ENTER' () key (notice the underlined character). The alarm type may now be selected by pressing the and. Alarm type options are Optical Density, Opacity and Dust. Once a selection has been made press the ENTER' () key to continue (notice no underlined characters) or EXIT key to return to the Alarm 1 display. Alarm 1 Trip (AL1 trip) Select AL1 trip: 0.00 by pressing the and keys from the Alarm type display (notice no underlined characters). Now press the ENTER' () key (notice the underlined character). The alarm trip may now be set to a value between 0 and 1000 by pressing the and keys. Once set press the ENTER' () key to continue (notice no underlined characters) or EXIT key to return to the Alarm 1 display. Alarm 1 Delay (Delay) Select Delay: 5s by pressing the and keys from the Alarm trip display (notice no underlined characters). Now press the ENTER' () key (notice the underlined character). The alarm delay may now be set between 0 and 30 seconds by pressing the and keys. Once set press the EXIT key to return to the Alarm 1 display. SETUP ALARMS (ALARM 2) Alarms AL1 type: O.D. From the Alarm menu press the ENTER' () key to access 'Alarm 2'. It is now possible to scroll through three options type, trip and delay by pressing the and keys. Setting these values is identical to the procedure for alarm 1 above. 111

122 Model 4500 MkI I+ Dust and Opacity Monitor SETUP MISCELLANEOUS (MISCELLANEOUS) Installation and Maintenance Manual On selection press the ENTER' () key. The miscellaneous menu gives access to a number of additional functions: Align Dust Gain Show -ve Display Dust Offset O/P1 range OP 0 limit O/P2 range Station number Access to these functions is gained as illustrated below. Return to the Miscellaneous display by pressing the EXIT key when no underlined characters are displayed. SETUP Signal: xxx.x Outputs* Alarms* Miscellaneous Service* Align Opac. Display: % O/P1 range: 4-20 O/P2 range: 4-20 Dust Gain: x Dust Offset: x OP0 Limit: x Station No.: x Link Not fitted Show -ve: No Opac. Display: % O/P1 range: 4-20 O/P2 range: 4-20 Dust Gain: x Dust Offset: x OP0 Limit: x Station No.: x Link: Not fitted Link: Not fitted 112

123 Installation and Maintenance Manual Signal: xxx.x Alignment of Instrument (Align) Model 4500 MkI I+ Dust and Opacity Monitor On selection press the ENTER' () key to display the alignment value. Align the instrument along its optical axis (see Using The Instrument for the First Time section) to display the maximum value. The alignment value is very useful when bright sunlight makes the alignment target may be visible. Press the ENTER' () key to return to the Align display, it is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. Opac. Display: % IO/P1 range: 4-20 IO/P2 range: 4-20 Display Units (Display) On selection press the ENTER' () key (notice the underlined character). The opacity units may be selected between a percentage or a numerical value. Press the or key to select the required units then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous submenu by pressing the keys. Signal Output Range (O/P 1 range) On selection press the ENTER' () key (notice the underlined character). Signal outputs may be set to one of three options 4-20, 2-20 and 0-20 ma. Press the or key to select the required units then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous submenu by pressing the keys. Signal Output Range (O/P 2 range) On selection press the ENTER' () key (notice the underlined character). Signal outputs may be set to one of three options 4-20, 2-20 and 0-20 ma. Press the or key to select the required units then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous submenu by pressing the keys. Dust Gain: x Dust Gain On selection press the ENTER' () key (notice the underlined character). The Dust Gain is automatically set from a single isokinetic sample or input manually with the figure obtained from a graph of multiple isokinetic samples. (See calculating the Dust Gain). Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. 113

124 Model 4500 MkI I+ Dust and Opacity Monitor Dust Offset: x Dust Offset Installation and Maintenance Manual On selection press the ENTER' () key (notice the underlined character). The Dust Offset value sets a base line offsets in dust calibration) It is recommended that this value is set to zero. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. OP0 Limit: Station No.: Link: Show -ve: x x Not fitted No Output Zero Limit (OP0 Limit) On selection press the ENTER' () key (notice the underlined character). The Output Zero Limit value sets the minimum opacity value to be displayed (default setting of 0.04 or 4%). This complies with EPA legislation (USA). See Error Message No 4 in Fault Finding section of the Reference manual. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous submenu by pressing the keys. Station Number (Station No.) On selection press the ENTER' () key (notice the underlined character). The Station Number indicates the location of the instrument to the user control system via the MODBUS communication protocol. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. Link (Not fitted) On selection press the ENTER' () key (notice the underlined character). The User interface requires indication no link has been fitted. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. Do not change this value without authorisation from Land Instruments. Show negative values (show -ve) On selection press the ENTER' () key (notice the underlined character). Negative opacity values may be shown for diagnostic purposes and are required by certain regulatory agencies. Press the or key to select the required value then press the ENTER' () key to set the option (notice no underlined character). It is now possible to scroll through the Miscellaneous sub-menu by pressing the keys. 114

125 Installation and Maintenance Manual SETUP SERVICE (SERVICE) Model 4500 MkI I+ Dust and Opacity Monitor This menu only permits access with an entry code and is reserved for the use of LAND service personnel. Press the or keys to scroll through the Setup menu or press the EXIT key to return to the menu spine. SETUP Outputs* Alarms* Miscellaneous* Service Entry Code: xx 115

126 Model 4500 MkI I+ Dust and Opacity Monitor C4-5 Display Screens Installation and Maintenance Manual DISPLAY (DISPLAY) On selection of Display on the menu spine press the ENTER' () key. Two Display menus Top Line and Bottom Line can be scrolled through by pressing the or keys. The display is customised by selecting the required display (see below) for both the top line and the bottom line of the display. To return to the Display menu and set the selection made press the EXIT key. DISPLAY Top line Bottom line Optical Density* Optical Density* Setting Top Line Display On selection of Top Line press the ENTER' () key. Press the or keys to scroll through the options available and then press the ENTER' () key again to set the option selected. The selection will appear on the top line of the display. To return to the Top Line sub-menu press the EXIT key. Options available are as follows: Opacity (displays opacity value) Optical Density (displays optical value) Dust Density (displays dust density value) Chan. 1 Average (displays average value of channel one) Chan. 2 Average (displays average value of channel two) Status (displays system status faults) Loop O/P 1 (displays current loop output 1 reading in ma) Loop O/P 2 (displays current loop output 2 reading in ma) Last Zero (displays last zero calibration value) Last Span (displays last span calibration value) Cal. Drift (displays drift between calibrations - range 0.1 to 1.0) Version (displays software version number) Blank (displays a blank line) See next page for setting bottom line 116

127 Installation and Maintenance Manual Setting Bottom Line Display Model 4500 MkI I+ Dust and Opacity Monitor On selection of Bottom Line press the ENTER' () key. Press the or keys to scroll through the options available and then press the ENTER' () key again to set the option selected. The display will not change until the maintenance switch has been returned to the RUN (vertical) position. To return to the Bottom Line sub-menu press the EXIT key. Options available are as follows: Opacity (displays opacity value) Optical Density (displays optical value) Dust Density (displays dust density value) Chan. 1 Average (displays average value of channel one) Chan. 2 Average (displays average value of channel two) Status (displays system status faults) Loop O/P 1 (displays current loop output 1 reading in ma) Loop O/P 2 (displays current loop output 2 reading in ma) Last Zero (displays last zero calibration value) Last Span (displays last span calibration value) Cal. Drift (displays drift between calibrations - range 0.1 to 1.0) Version (displays software version number) Blank (displays a blank line) 117

128 Model 4500 MkI I+ Dust and Opacity Monitor C4-6 Parameter Screens Installation and Maintenance Manual SO* PARAMETERS PARAMETERS This menu contains the Model 4500 MkII + internal parameters and is used as a general software dump with updated readings. It is not normally intended for customer use, but may be useful for diagnosing particular problems. On selection of Parameters on the menu spine press the ENTER' () key. Press the or keys to scroll through the parameters available for viewing, as detailed below. So... Signal detector offset Sf... Signal detector flood value Sm... Signal detector measurement Ro... Reference detector offset Rf... Reference detector flood value Rm... Reference detector measurement C... Dust concentration X... Calibration constant B... Balance correction G... Gain correction factor Q... Uncorrected transmission factor Dust Gain... Constant relating Optical Density to Dust Density. Dust Offset... Optical Density v Dust Density zero offset (usually zero) Zero Damper... Low pass digital filter applied to zero reading Flood Damper... Low pass digital filter applied to flood LED Cal Damper... Low pass digital filter applied to calibration OP 1 Damper... Low pass digital filter applied to output 1 OP 2 Damper... Low pass digital filter applied to output 2 PLCF... Path Length Correction Factor OPLR... Optical Path Length Ratio (0.5 x PLCF) Last Cal.... Data stored from the latest calibration Zero Comp.... Opacity compensation due to dust build on the lens Isokinetic O.D.... Optical Density Calculated Isometrically Version x.xx... Identification of software version used 118

129 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor C5 System Specification C MkII + Dust and Opacity Monitor Measuring Technique: Operating Wavelength: Light Source: Double pass/path transmissometry 520 ± 20 nm High Intensity LED Range: Opacity 0 20 % to % Optical Density to Dust Density to 0 to 4000 mg/m 3 User Selectable Linearity: Resolution: Drift: Angle of Projection: Angle of View: Response Time: Averaging: Pathlength: Calibration: Zero Correction: < 2 % of range 0.1 % Opacity; Optical Density; 0.1 mg/m 3 Dust < 1 % of range per month < 2 o < 2 o 1 second to 90 % of final value Selectable from instantaneous to 59 minutes 0.7 to 10 m (2 to 33 ft) or optionally up to 20 m (66 ft) Automatic zero and upscale calibration (Selectable interval 1 to 24 hours in 1 hour steps) Automatic correction for zero drift Control Panel Display: Keypad: Indicators: 2 x 16 character reflective backlit LCD with adjustable contrast control 7 keys for data input System OK, Alarm 1, Alarm 2, Zero calibration, Span calibration Weight Transceiver 15.2 kg (33 lb) with fail-safe shutters 19.2 kg (42 lb) Retro-reflector 8 kg (17.6 lb) with fail-safe shutters 11.6 kg (25.5 lb) 119

130 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Environmental Operating temperature: -20 to 55 o C (-4 to 131 o F ) (-40 o C / -40 o F with optional heater) Maximum Flue Gas temperature: Maximum Flange Temp: Environmental rating: 600 o C / 1112 o F 200 o C / 400 o F IP66 / NEMA4X Compliance Measurement standards: Safety: Meets or exceeds US EPA requirements for 40CFR60 Sections 13, 17 and App. B PS1 Meets or exceeds US EPA requirements for proposed Method 203 Meets or exceeds ASTM Standard D and D TUV approved to the requirements of 13th BImSchV and TA Luft Conforms to EN EMC: Conforms to E & EN Outputs Modbus Interface: Analogue Outputs: RS232 or RS485. Opacity, Dust, Optical Density, Status, Averaging and Range information available Two isolated 4-20mA current outputs. Independently configurable as Opacity, Dust Optical Density, Calibration Drift or PLCF Relay Outputs: System OK, Span calibration, Zero calibration, Alarm 1, Alarm 2, Maintenance Continuous product development may make it necessary to change these details without notice. 120

131 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Termination Box Modbus Interface: Analogue Outputs : Relay Outputs: Relay Rating: Standard Termination Box Power Supply: Power Consumption: Heated Termination Box Power Supply: Power Consumption: Installation Category: RS232 or RS485 Multi-drop Opacity, Dust, Optical Density, Status, Averaging and Range Information available Calibration sequence trigger Two 4-20mA current loops, fully isolated 50 V d.c. Independently configurable as: Opacity, Dust, Optical Density or Calibration Drift System OK, Span Calibration, Zero Calibration, Alarm 1, Alarm 2, Maintenance Single Pole Changeover 2A at 40 V d.c.; 2A at 230 V a.c. 90 to 260 V a.c. (universal input), 50 to 60 Hz 10 W 115 / 230 V a.c. (dual voltage, selectable) 50 to 60 Hz 60 W Category II Electromagnetic Compliance: Conforms to EN ; EN Operating Temperature: Dimensions (H x W x D): Weight: -20 to +55 C (-4 to +131 F) 180 x 400 x 120 mm (7 x 16 x 5 inches) 7.5 kg (16.5 lb) Continuous product development may make it necessary to change these details without notice 121

132 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual C6 Testing and Checking C6-1 Identifying Faults The Land Model 4500 MkII + Dust/Opacity Monitor has been designed to allow the user to troubleshoot a number of possible problems and faults. If a fault condition occurs, the system OK LED on the transmissometer will not be illuminated and the System OK relay will reset to Fault condition. Error messages may be read by pressing the Maintenance switch for 3 seconds to enter Maintenance mode, and pressing the ENTER key at the Faults menu. The display will show the number of faults, further depression of the ENTER key will display a series of fault messages. NOTE Non-fatal faults are reset once they have been viewed. ERROR DESCRIPTION DIAGNOSIS NUMBER - LEDs off. No power at T-Box - check power supply. Display blank. Check fuse. - LEDs on. Adjust contrast with Contrast key. Display blank. - Instrument reads constant Beam blocked - check fail-safe shutters. high opacity value Check for beam blockage. Transceiver not connected. Umbilical cable damaged. 0 Checksum error Fault in instrument memory call LAND Combustion Service Dept. 1 EEPROM Write error 2 OP0 fault Zero check failed. Repeat cal. check. 3 OPc fault Span check failed. Repeat cal. check. 4 OP0 limited Zero cal. value out of range- several causes: Dirty window - clean optics (see Maintenance). Instrument drift - check and re-calibrate. Repeat cal. check. 5 Fail in cal. Calibration failed or aborted. Repeat cal. check. Check cal. motors and micro-switches. 122

133 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor ERROR DESCRIPTION DIAGNOSIS NUMBER 6 Motor jammed Zero or span cal motors failed to park. Check motors and micro-switches. 7 Measure LED fail Signal LED failed. Check connections. Replace LED. 8 Flood LED failed Flood LED failed. Check connections. Replace LED. 9 ADC over-range Analogue to Digital Converter value too high. Check correct aperture fitted on Retro-Reflector. Call LAND Instruments International Service Dept. 10 ADC fault Analogue to Digital Converter failed to convert. Call LAND Instruments International Service Dept. 11 Gain Drift Flood LED fault during calibration. Repeat calibration. If fault persists call LAND Instruments International Service Dept. 12 Filter blocked Air Filter pressure switch activated. Clean/replace air filter. Check wiring between pressure switch and T-Box. 13 Blower failure Blower pressure switch activated. Check blower power supply. Check blower motor. Check wiring between pressure switch and T-Box. 14 Negative opacity Opacity value < -5% New installation: Check the path length is correct. Calibration error: Check calibration. Re-calibrate if necessary. IMPORTANT Whenever the Land Service Department is contacted regarding problems with an instrument, please have available information on the instrument type and serial number. This will enable the department to respond more accurately and efficiently. 123

134 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual C6-2 Maintenance The Land Instruments International Model 4500 MkII + has been designed for a minimal amount of routine maintenance. To ensure a maximum monitor lifetime however, the following maintenance schedule has been developed. Remember that the air purge system should always be left on, even if the boiler is off, to prevent any contamination of the optics. In exceptionally dirty facilities, the time periods below should be shortened. Frequent Op0 limited alarms or blower faults may indicate a need to shorten the maintenance period. ITEM MAINTENANCE PROCEDURE Air Hoses 90 Days Examine hoses for holes or leaks. Test all hose clamps for tightness. Pre-filter 90 Days Dust level should be below the line. (Where fitted) Remove, empty, wipe out, and replace. Filter cover 90 Days Remove the filter from the filter housing. /Rubber cup Remove the rubber cup. Empty the cup, (Where fitted) wipe out, and replace. Filter Element 90 Days Wear eye protection, tap gently to remove dust. Clean carefully with a blow gun. Examine for holes or rips. Re-fit. Annually Replace with new filter. Blower 90 Days Check for bearing noise. (Bearing failure, and subsequent blower failure, can be detected early.) Check blower air flow to be sure that the blower is performing normally. (Dirty air filters may reduce air flow and cause undue stress on the blowers.) Optics 90 Days Check and clean the optics as described below. Air Purge 90 Days Open the Transceiver or Adapter Retro-Reflector on its hinge and check that there is no ash buildup inside the adapter that could block the light path. 124

135 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor During the regularly scheduled maintenance periods, any optional equipment (e.g. shutters, pressure switches, weathercovers) should be checked for correct operation. If any potential problems are noted, the equipment should be repaired or replaced if necessary. Cleaning the Optical Surfaces After prolonged use, it is likely that some contamination will occur on the optical surfaces of the Model 4500 MkII +. The time taken for significant contamination to occur depends very much on the nature of the installation, but in a typical situation it should be sufficient to clean the optics every 90 days. Three optical components should be cleaned, using the lens cloth supplied by Land Instruments International. CAUTION Always use a lint free lens cloth to clean the optical surfaces. Ensure the cloth is kept clean. A dirty lens cloth can scratch the optical surface and cause permanent damage to the Model 4500 MkII +. Replacement lens cloths can be purchased from Land Instruments International. Ordinary tissues and dusters are not suitable, and can scratch the delicate optical surfaces. To clean the Retro-Reflector, open the housing by undoing the two quick-release clamps. Loosen the aperture plate non captive screws and remove the plate over the Retro-Reflector (if fitted), carefully wipe the surface of the Retro-Reflector with the lens cloth, then replace the aperture plate. Close the housing and fasten the two quick-release clamps. To clean the mains lens, open the Transmissometer housing by undoing the two quick-release clamps. Undo the two socket headed, captive screws holding the zero-point assembly and carefully remove it. Wipe the lens using the lens cloth, then replace the zero-point assembly. Lift the springloaded protective cover over the zero-point reflector and wipe the reflector. Gently replace the protective cover. Close the housing and fasten the quick-release clamps. CAUTION Do not attempt to move the zero-point reflector by hand. The precision gearbox will be irreparably damaged. Cleaning the Termination Box It is recommended to periodically clean the termination box to remove any build-up of dirt or dust, which may enter the box if the door is opened. 125

136 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Changing the pathlength The Model 4500 Premier has been configured and tested for the pathlength specified at the time of purchase. Changing its pathlength will alter its calibration and may invalidate any certificate of compliance. Do not change the installation pathlength without authorization from Land Instruments International. Tools required 2.5 mm hex (Allen) key 5 mm hex (Allen) key - supplied Set the correct focus 1. Open the transceiver housing by undoing the two quick-release clamps. 2. Undo the two socket headed, captive screws holding the zero-point assembly and carefully remove it. 3. Undo the 3 M4 socket headed screws holding the lens assembly. NB These screws are NOT captive. 4. Carefully remove the lens assembly, taking care not to touch the lens surface. 5. Remove the o-ring from the lens and remove the focus spacers. There are 3 spacers, with thicknesses 2 mm, 4 mm and 8 mm. Select the appropriate spacers to give the correct focus distance for the flange-to-flange pathlength shown in the table. 6. Replace the O-ring on the lens assembly. 7. Select the correct length of M3 fixing screws for the flange-to-flange pathlength shown in the table. Carefully place the screws into the holes in the lens assembly, making sure that they pass through the holes in the focus spacers. 8. Slide the lens assembly into place. 9. Fasten all of the screws using a 2.5 mm hex (Allen) key. 10. Replace the zero-point assembly. 11. Close the housing and fasten the quick-release clamps. Fit the correct retroreflector 1. Open the retroreflector housing by undoing the two quick-release clamps. 2. Undo the two M3 socket headed screws holding the retroreflector assembly and carefully remove it. NB These screws are NOT captive 3. Select the correct retroreflector for the flange-to-flange pathlength shown in the table. Fit the retroreflector using the M3 socket-head screws. 4. Close the housing and fasten the quick-release clamps. Perform a clear stack calibration at the new pathlength see B

137 Operation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Focus table Pathlength (m) Pathlength (inches) Spacer Retro Min Max Min Max

138 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual C6-3 Replacement Parts and Consumables Consumables Description... Part Number Lens Cloth Flange Sealing Ring Spares Parts Spherical Washer Spring Washer M12 Locknut Flange Stud Microprocessor Module PCB Signal Processor PCB Measurement Detector PCB Reference Detector PCB Source LED PCB Flood LED PCB Air Purge Diffuser Mains Lens Assembly Retro-Reflector Assembly (short path) Retro-Reflector (short path) Retro-Reflector Assembly (long path) Zero Calibration Assembly Zero Calibration Motor Assembly Zero Calibration Micro Switch Assembly Upscale Calibration Assembly Upscale Calibration Motor Assembly Upscale Calibration Micro Switch Assembly Calibration Grating Set Reflector Aperture Set Termination Box PCB (Not including enclosure) Termination Box PCB(Not incl. enclosure (Heated version) Transceiver cover fitted with key panel + connectors Control Panel PCB Year Spares Kit

139 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Identifying Spare Parts Lens Cloth (Part Number ) Flange Sealing Ring (Part Number ) Spring Washer (Part Number ) M12 Locking Nut (Part Number ) Spherical Washer (Part Number ) Flange Stud (Part Number ) 129

140 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Microprocessor Module PCB (Part Number ) Signal Processor PCB (Part Number ) Reference Detector PCB (Part Number ) Measurement Detector PCB (Part Number ) Control Panel PCB (Part Number ) Source LED PCB (Part Number ) 130 Flood LED PCB (Part Number )

141 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor Air Purge Diffuser (Part Number ) Main Lens Assembly (Part Number ) Retro-Reflector assembly (Part Number short path) (Part Number long path) (Reflector only short path) Zero Calibration Assembly (Part Number ) Zero calibration motor assembly (Part Number ) Zero calibration micro switch (Part Number ) Transmissometer Housing incl. key panel and connector (Part Number ) 131

142 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual Termination Box PCB (Part Number ) 132

143 Installation and Maintenance Manual Model 4500 MkII + Dust and Opacity Monitor C7 How to Get Further Assistance Technical Assistance Contact your local office, agent or distributor see front of manual for addresses or visit our website 133

144 Model 4500 MkII + Dust and Opacity Monitor Installation and Maintenance Manual C8 Configuration Record Sheet Please complete the Configuration Record Sheet. General Information Instrument Serial Number Date of Purchase Technical Information Pathlength Service History Date Action Repair History Date Action Part Replaced Part No.

145 Appendix Appendix A Aperture & Grating Selection Tables Model 4500 MkII + Dust and Opacity Monitor AppA-1 Automatic Zero Point Reflector Aperture and Grating Selection Aperture B Value Plate Grating A Grating 1 Grating 2 Grating 3 Grating 4 Grating 5 B C D E F G H I J K Select the Aperture Plate (horizontally) and the Grating (vertically) that relate to the 'B' value observed after re-calibration. AppA-2 Span Filter Grating Selection Grating Identification Opacity Rating R 45% T 36% V 28% W 20% X 15% Y 10% Z 5% i

146 Model 4500 MkII + Dust and Opacity Monitor Appendix Appendix B Low Temperature Termination Box AppB-1 Termination Box Heater Unit 1.1 Thermostatically Controlled Heated Local Control Unit Brief Description A 40W heater pad is pre-wired behind the PCB and controlled via a thermostat switch located on the underside of the main PCB. When the temperature inside the Termination Box drops below a preset value on the thermostat switch, the heater pad is activated. It is deactivated when the temperature returns to the preset value, and so a constant operating temperature is maintained. The thermostat switch is factory set to 0 C (32 F) and should require no further alteration. Electrical Designation The Termination Box is fitted with an additonal set of connectors when specified with the heater package. The additonal connectors are labelled A, B, C and D, and are fitted to the left of the main rail. The Termination Box is suitable for both 110 V and 230 V mains power. The power supply terminals are clearly marked with a label marked 'Heater'. A B C D 115V 230V HEATER! NOTE: THE UNIT IS FACTORY SET TO 230 V AND NO ADJUSTMENT IS NECESSARY Setting the Heater unit to accept 110 V mains supply 1. Ensure that the mains power supply is disconnected before proceeding. 2. Release the screws in terminals B and C. 3. Remove the two short (pre-fitted) cable links from their respective connectors. 4. Using the label for guidance, re-fit the cable links as indicated. One for each pair of connectors: A and B C and D 5. No further adjustment is necessary. Re-apply mains power supply. ii

147 Gas Monitoring Products Standard Terms of Warranty Land Instruments International warrant all products of our own manufacture to be within specified limits of calibration, if any, when despatched from our works. Also that they are free from defects in material and workmanship for normal use and service when used for their intended purpose within the limits of our specification. The period of warranty, with respect to defects in material and workmanship, will be one year from date of despatch, or readiness for despatch should delivery be delayed by the customer who has been notified of the readiness at or after the acknowledged estimated date of despatch. Land Instruments International guarantees to repair any defective workmanship or replace at its own option any defective parts in any product of its manufacture, provided that the defective instrument is returned to our works free of charge and securely packed. Also, provided that the said goods are found to be solely defective due to faulty design, materials or workmanship and not by improper use or accident. Items which under their normal course of use or storage, age or deteriorate e.g. measuring cells, batteries, vacuum tubes, thermocouples, are not covered by this warranty, and will be charged for if replaced together with labour charges for any work found not to be covered by the warranty and any transport or import charges incurred by Land Instruments International at the customers expense. Equipment or components purchased by Land Instruments International from other manufacturers and used with or within Land Instruments International equipment bear only the warranty of the original manufacturer. Warranty work will only be carried out on site on receipt of an official order from the customer who will be charged for all travelling time plus travelling and living expenses involved to carry out the work. Should the said faulty operation not be the cause of the instrument s faulty design, materials or workmanship, but due to application conditions, Land Instruments International reserve the right to charge additionally for all labour on establishing this at the customer s works. Warranty cover is subject to the correct planned maintenance being done in accordance with the published service schedule. Failure to follow the planned maintenance will void the warranty terms. Any warranty claim in this event will be at the discretion of Land Instruments International. Whilst every care is taken in the manufacture of our products, we can accept no responsibility for any consequential loss, however caused, through the failure of any of our products to operate accurately or correctly. All products except 4500mkIII The standard warranty on new instruments is a 1-year return-to-base warranty, including all electrochemical cells.. If repairs are performed at site, then travelling time and expenses will be charged at standard rates. Purchased Spare Parts are warranted for 1 year from date of shipment, carriage included. If a Spare Part is supplied under warranty, then this part is only warranted for the residue of the applicable warranty period. Calibration filters are not warranted against any damage or change in characteristic that may occur due to mishandling. Model 4500mkIII The standard warranty on new instruments is a 3-year return-to-base warranty. If repairs are performed at site, then travelling time and expenses will be charged at standard rates. Purchased Spare Parts are warranted for 1 year from date of shipment, carriage included. If a Spare Part is supplied under warranty, then this part is only warranted for the residue of the applicable warranty period. Calibration filters are not warranted against any damage or change in characteristic that may occur due to mishandling. The 4500mkIII light source has a lifetime warranty. Exclusions 1. Warranty subject to the analysers being used in the manner for which they were designed 2. Warranty subject to all recommended maintenance being performed as defined in the operating or service manual or in the quotation 3. The following consumable items are specifically excluded: All filters, Chemical filters, Chemical Drying Agents, Batteries. Rev 5 Jan 2012