ems500 opacity/dust monitor -...

EMS500 Opacity/Dust Monitor Installation and Operation Manual Rev 2.7

OCOTOBER 03, 2017

PREPARED BY MICHAEL L. KOMINSKE

Environmental Monitor Service Inc. PO Box 4340 Yalesville, CT 06492 Phone 203.935.0102 Email: [email protected]

[email protected]

2

CUSTOMER SERVICE ............................................................................................................................................................ 4

SECTION 1 - SYSTEM DESCRIPTION AND SPECIFICATIONS .................................................................................................... 5

PRICIPAL OF OPERATION ................................................................................................................................................................ 5

REMOTE CONTROL UNIT (RCU) ..................................................................................................................................................... 6

EMS500 OPACITY SPECIFICATIONS ................................................................................................................................................. 7

TRANSCEIVER/ REFLECTOR ............................................................................................................................................................. 8

SEVER WEATHER COVER ............................................................................................................................................................... 9

PURGE BLOWER ELECTRICAL AND PRESSURE INFORMATION ................................................................................................................. 10

SECTION 2 INSTALLATION CONSIDERATIONS ..................................................................................................................... 11

REGULATORY/PROCESS CONSIDERATIONS ....................................................................................................................................... 11

APPENDIX B TO PART 60—PERFORMANCE SPECIFICATIONS ............................................................................................................... 12

STACK EXIT CORRELATION COMPUTATIONATIONS............................................................................................................................. 17

INSTALLATION – MECHANICAL ...................................................................................................................................................... 19

MOUNTING THE AIR PLENUM AND WEATHER COVERS ........................................................................................................................ 23

BEAM ALIGNMENT PROCEDURE .................................................................................................................................................... 26

SECTION 3 CONTROL UNIT (RCU) OPERATION PAGE DESCRIPTION .................................................................................... 27

RCU UNIT BUTTONS ................................................................................................................................................................... 27

ABOUT PAGES ............................................................................................................................................................................ 28

OPERATOR PAGES ...................................................................................................................................................................... 30

PASSWORD PROTECTED TECH PAGES ............................................................................................................................................... 33

SECTION 4 MODBUS .......................................................................................................................................................... 40

RS/485 COMMUNICATIONS AND CONNECTION ............................................................................................................................... 41

SECTION 5 -OPTIONAL OUTPUT/RELAYS ............................................................................................................................ 43

CHANNEL #1 AND 2 FULL SCALE SET UP........................................................................................................................................ 43

OPTIONAL ALARM RELAYS ........................................................................................................................................................... 43

SECTION 6 – CLEAR PATH ADJUSTMENTS........................................................................................................................... 45

SECTION 7 - PREVENTIVE/CORRECTIVE MAINTENANCE ..................................................................................................... 46

SECTION 8 - DRAWINGS ..................................................................................................................................................... 47

EMS-3203 ELECTRICAL WIRING CONNECTION ............................................................................................................................... 49

RECOMMENDED SPARE PARTS .......................................................................................................................................... 51

SECTION 9 DUST ................................................................................................................................................................ 52

CORRELATION WITH PARTICULATE/DUST DENSITY ............................................................................................................................. 52

READING RECORDED DATE FROM THE SD CARD ................................................................................................................ 57

TO READ DATA FROM SD CARD, UNITRONICS SUITE PROGRAM MUST BE INSTALLED ON PC. ............................................... 57

3

LIMITED WARRANTY

EMS warranty is found in the CD supplied with monitor shipment. If you cannot find it or you have misplaced it contact EMS at [email protected] and request the

current Limited Warranty document.

WARNINGS AND SAFETY GUIDELINES

GUIDELINES FOR USER SAFETY AND EQUIPMENT PROTECTION

This manual is intended to aid trained and competent personnel in the installation of this equipment. Only a technician or engineer

trained in the local and national electrical standards should perform tasks associated with the electrical wiring of this device.

WARNINGS

▪ Under no circumstances will Environmental Monitor Service, Inc. be liable or responsible for any consequential damage that

may arise because of installation or use of this equipment.

▪ All examples and diagrams shown in the manual are intended to aid understanding. They do not guarantee operation.

▪ Environmental Monitor Service, Inc. accepts no responsibility for actual use of this product based on these examples.

▪ Due to the vast variety of possible applications for this equipment, the user must assess the suitability of this product for

specific applications.

▪ Make sure to have safety procedures in place to stop any connect3ed equipment in a safe manner if the controller should

malfunction or become damaged for any reason.

▪ Do not replace electrical parts or try to repair this product in any way.

▪ Only qualified factory trained service personnel trained in is operation should open the device’s housing or carry out repairs.

▪ The manufacturer is not responsible for problems resulting from improper or irresponsible use of this device.

▪ You may cause an electric shock, fire or damage the equipment if you ignore any of these safety precautions.

mailto:[email protected]?subject=Limited%20Warranty%20document%20request

4

CUSTOMER SERVICE

Before you ship equipment to our factory please call or email our Service Response Center at 1-800-864-2814 ext 14. When you call in, our

Customer Service Representative will determine a course of action.

E-mail: [email protected]

CLAIMS FOR DAMAGED SHIPMENTS

Inspect all instruments thoroughly on receipt. Check material in the container (s) against the enclosed packing list.

If the contents are damaged and/or the instrument fails to operate properly, notify the carrier and Environmental

Monitor Service immediately.

The following documents are necessary to support claims:

Original freight bill and bill of lading

Original invoice or photocopy of original invoice

Copy of packing list

Photographs of damaged equipment and container

You may want to keep a copy of these documents for your records also.

Refer to the instrument name/model number, serial number, sales order number, and your purchase order

number on all claims. Upon receipt of a claim, we will advise you of the disposition of your equipment for repair or

replacement.

SHIPPING DISCREPANCIES

Check all containers against the packing list immediately on receipt. If a shortage or other discrepancy is found, notify the

carrier and Environmental Monitor Service immediately.

EMS will not be responsible for shortages against the packing list unless they are reported within 3 days of receiving of your shipment.

5

SECTION 1 - SYSTEM DESCRIPTION AND SPECIFICATIONS

The Model EMS500 Opacity Monitor provides continuous, minimal maintenance, precision measurement of opacity in

industrial applications. It is a cost-effective instrument that serves as an aid in operating pollution and/or process control

equipment.

PRICIPAL OF OPERATION

The Dual beam measurement system has a stack mounted Transmissometer sensor system consisting of an optical

transceiver mounted on one side of the stack and a retro reflector mounted on the other. To avoid errors due to

ambient light, the lamp is electronically modulated and projects a collimated beam of light, which is split into a

reference beam, and a measurement beam by an optical Beam splitter. The reference beam is directed to the

reference detector, RD. The measurement beam is projected across the stack to a Retro reflector that returns the

beam back across the stack to a beam splitter and directs the measurement beam to the measurement detector,

MD. A portion of the returning

light is also sent to the TTL (Thru

the Lens) bulls-eye target viewed

through a window provided at

the rear of the Transmissometer.

The bulls-eye is used to correct

changes in alignment and is

unique in that no moving parts

are used!

The ratio of the measurement

and reference detectors is used

to provide Transmittance (T 2)

signal. Because the same light

source is used for both

detectors, and a Measurement / Reference ratio is used throughout for the calculations, the monitor is insensitive

to variations in light intensity. Since all measurements are made on a ratio basis, all resulting computations are

independent of the absolute intensity of the light source or contamination of the optics associated with the

collection and focusing of the energy from the lamp. The (T 2) signal is converted to a current format and sent to

the RCU for processing. At the control unit, the signal is processed to read 0-100% Opacity, provide alarms and

outputs.

The function of the reflector is to return the measurement beam to the detector in the transceiver, creating a

double pass across the process stream.

6

REMOTE CONTROL UNIT (RCU)

The Ems500 control unit provides instrument control functions, opacity

readings, alarm and fault indicators, analog outputs, and diagnostics with

contact closures and more. The RCU can be DIN rail mounted or panel

mounted (3.7x3.7” – 93x93mm) in a control room environment and is

rated NEMA 4X/IP65 when panel mounted. Battery backup for all memory

is typically 7 years.

The control unit should be mounted in a control room environment i.e., clean,

temperature with max/min of +0o to +50 o C (+32 o to + 122 o F).

OPTIONAL AIR PURGE WEATHER COVER SYSTEM

The transceiver and reflector may be mounted in weather covers. The weather covers are compact to allow movement

around them even on a three-foot walkway or platform. They protect the stack-mounted

components from dirt, moisture; stack temperatures within the specified ambient temperatures

limits, and errant air currents around the stack.

The air purge system constantly circulates air past the optical window. The air flow is directed

through the hose to an air plenum on the stack side of the optical window. The air flow in the air

plenum area results in reduced pressure and increased velocity. This venturi effect tends to

continually draw the air around the optical window into the purge air stream, thereby keeping the

lens clean for extended periods.

ALIGNMENT SYSTEM

The EMS500 includes a built-in through-the-lens alignment system. The alignment target can be viewed through a window

on the transceiver. Adjustments to changes in alignment are provided by a 3-point alignment system, which is integral to

the air plenum.

RS 485 CABLING RECOMMENDATION

Use cables to network devices that meet specs of Belden Cable P/N 3106A Multi -Conductor – EIA Industrial RS-485

PLTC/CM or equivalent:

• 22AWG stranded (7x30) tinned copper conductors, Datalene insulation, twisted pairs, overall Beldfoil

shield(100% coverage) plus a tinned copper braid(65% coverage), drain wire, UV resistant PVC jacket.

• Impedance of 120 ohms

• Network cables cannot exceed 1219 meters, 4,000 ft.

If Longer distance is required, wireless option should be considered. Please contact the factory.

7

EMS500 OPACITY SPECIFICATIONS

EMS500 Opacity Control unit: Environmental Monitor Service, Inc.

Enclosure IP65/NEMA4X (when panel mounted),

96x96x64mm (3.8" x 3.8" x2.58"). Power

24Vdc +/- 10%.

EMS provided 24Vdc Supply Input: 90-240 VAC, 50/60 Hz, 0.55 amp

+10%

Graphic Display 1.5x2.25” Viewing area, LED Backlight

Approvals CE, UL, cUL

Measurement Ranges -5 to 99% Opacity

Display Resolution 1% for Opacity

Process Display screens Selectable pages, Opacity

Battery back up 7 years typical at 25oC

S.D. Card Optional - Back up by SD memory card.

2-wire to EMS Control Unit RS485 Modbus to Control Unit

Relay Contacts 6 relays for alarms, Field programmable.

Alarm Reset Automatic and manual.

Clear Path Calibration Push button Digital Auto Linearity, Z/S,

Gain and LED current.

OPLR (Exit Correlation Lx /

2*Lt)

0.3 to 1.0

Environment Inside cabinet IP20 / NEMA1 (case),

Panel mounted IP65 / NEMA4X (front

panel), Operational temperature 0 to

50ºC (32 to 122ºF), Storage temperature -

20 to 60ºC (-4 to 140ºF), Relative

Humidity (RH) 5% to 95% (non-

condensing)

Network Protocol: MODBUS, type RS-485.

8

TRANSCEIVER/ REFLECTOR

PS-1 Transceiver/ Reflector:

Enclosure NEMA 4 watertight enclosure.

Path Length Distance dependent.

Optical System PS-1 Double Pass

Reflector Distance dependent.

Light Source Aging

Compensation

Automatic

Light Source Life 62,000 hours (> 7 years) Field replaceable

without removal

Ambient Temperature Limits 0 to +130o F (-17 to +54o C) (Cold weather

option available).

Process Gas Up to 750o F (400 o C),

Alignment Verification Built-in through-the-lens system

standard

Mounting Flanges 3 inch IPS, 150# flange. Others available.

Ambient Light Immunity Solid-state modulation (Meets ASTM

D6216)

9

SEVER WEATHER COVER

Severe Weather Cover:

Material 308 Stainless Steel

Quick release pins 2 for bottom and 2 for top release.

Mounting 3 inch IPS, 150# flange. Others available.

Standard Blower 110/220VAC 50/60Hz

Max stack pressure +/- 5 inch WC, with the proper installation

of purge blowers.

Wind Speed < 60 mph

Ambient temperature limits -40oF to 130oF (-4oC to 54oC)

Protection for Transceiver and Retro-reflector

components; purge blowers.

10

PURGE BLOWER ELECTRICAL AND PRESSURE INFORMATION

Single Phase 110VAC 50/60Hz 220VAC 50/60Hz

Run Amps 3.4 1.7

H.P. 0.25 0.25

11

SECTION 2 INSTALLATION CONSIDERATIONS

REGULATORY/PROCESS CONSIDERATIONS

The EPA has established the following guidelines for choosing an opacity/dust density monitor installation site:

1) Locate the transmitter across a section of a duct or stack that will provide a particulate matter flow

through the path of the transmitter beam representative of the duct or stack flow.

2) Ensure the transmitter location is down-stream from all particulate control equipment.

3) Locate the transmitter as far from bends and obstructions as practical.

4) If a transmitter is to be located less than 4 duct diameters downstream from a bend, install the

transmitter in the plane defined by the bend, as shown in the figure below.

5) Ideally, locate the transmitter eight to ten stack diameters upstream from the stack exit and three

to five diameters downstream from any bends, junctions, or other constrictions in the stack or duct.

For best results, mount the transceiver and retro reflector modules so the light beam is exactly perpendicular to

the stack or duct and the beam goes through the center. Do not install the transmitter downstream of a wet

scrubber. The water droplets introduced to the gas stream by such equipment will interfere with the opacity

readings. For an accurate measurement under these conditions, choose a location upstream from a wet scrubber

or a location downstream from the scrubber where the water droplets are vaporized by the reheating of the gas.

The stack exit correlation is especially important to verify. If possible all dimensions should be verified by actual

measurements. Measure and record inside stack dimensions at the

measuring point and at the stack exit, and compute the Optical Path

Length Ratio (O.P.L.R.). Check that the calculated and the O.P.L.R. found

in the Factory OPLR Check step found further in this section are within

+/- 2%.

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APPENDIX B TO PART 60—PERFORMANCE SPECIFICATIONS

(2) You must install the opacity monitor at a location where the opacity measurements are representative of the total emissions from the affected facility. You must meet this requirement by choosing a measurement location and a light beam path as follows:

(i) Measurement Location. Select a measurement location that is (1) at least 4 duct diameters downstream from all particulate control equipment or flow disturbance, (2) at least 2 duct diameters upstream of a flow disturbance, (3) where condensed water vapor is not present, and (4) accessible in order to permit maintenance.

(ii) Light Beam Path. Select a light beam path that passes through the centroidal area of the stack or duct. Also, you must follow these additional requirements or modifications for these measurement locations:

If your

measurement

location is in a: And is: Then use a light beam path that is:

1. Straight vertical

section of stack or

duct

Less than 4 equivalent

diameters downstream from

a bend

In the plane defined by the upstream bend (see figure 1–1).


section of stack or

duct


diameters upstream from a

bend

In the plane defined by the downstream bend (see figure 1–2).


section of stack or

duct


diameters downstream and

is also less than 1 diameter

upstream from a bend

In the plane defined by the upstream bend (see figure 1–3).

4. Horizontal

section of stack or

duct

At least 4 equivalent


a vertical bend

In the horizontal plane that is between 1/3 and 1/2 the

distance up the vertical axis from the bottom of the duct (see

figure 1–4).

5. Horizontal

section of duct



a vertical bend

In the horizontal plane that is between 1/2 and 2/3 the

distance up the vertical axis from the bottom of the duct for

upward flow in the vertical section, and is between 1/3 and

1/2 the distance up the vertical axis from the bottom of the

duct for downward flow (figure 1–5).

13

(iii) Alternative Locations and Light Beam Paths. You may select locations and light beam paths, other than those cited above, if you demonstrate, to the satisfaction of the Administrator or delegated agent, that the average opacity measured at the alternative location or path is equivalent to the opacity as measured at a location meeting the criteria of sections 8.1(2)(i) and 8.1(2)(ii). The opacity at the alternative location is considered equivalent if (1) the average opacity value measured at the alternative location is within ±10 percent of the average opacity value measured at the location meeting the installation criteria, and (2) the difference between any two average opacity values is less than 2 percent opacity (absolute). You use the following procedure to conduct this demonstration: simultaneously measure the opacities at the two locations or paths for a minimum period of time (e.g., 180-minutes) covering the range of normal operating conditions and compare the results. The opacities of the two locations or paths may be measured at different times, but must represent the same process operating conditions. You may use alternative procedures for determining acceptable locations if those procedures are approved by the Administrator.

17

STACK EXIT CORRELATION COMPUTATIONATIONS

NOTE: The stack exit correlation is especially important to verify. If possible, all dimensions should be verified by actual measurements. Using the instructions below verify that the values are correct as displayed in the About page.

Lx/Lt is the ratio of the inside diameter at the top of the stack to the inside diameter of the stack where the

instrument is located (Figure 3-1). If the ratio is greater than 1.0, the exit opacity will be greater than the opacity at

the instrument location. The EMS 500 uses this correction factor to calculate the stack exit opacity. It is not

practical to have an Lx/Lt factor much greater than 2.0 because the error of the instrument increases as Lx/Lt

becomes greater.

Lx = inside stack diameter at stack exit.

Lt = inside stack diameter at the transmitter location.

Lf = flange to flange distance between the transceiver and retro reflector unit.

1) Measure and record Lx and Lt and compute the Optical Path Length Ratio (OPLR).

2) Check that the calculated value and the OPLR found in the 2nd About page are within ±2%.

3) Example: A stack with a 120 in. (3048 mm)

stack exit ID and a 120 in. (3048 m) path

length.

4) Enter the exit

diameter (Lx) and measured diameter (Lt) in

the control unit. Refer to Section 4: Operation,

for info on using the control unit.

Lt

LxOPLR

*2

50.0120*2

120OPLR

18

Choose an installation site; the primary considerations for choosing a site for the EMS411 are accessibility, ambient

environmental conditions, and locating the unit to obtain a representative sample of the process. Review the

excerpt from the Federal Register in appendix for suggestions before selecting an installation site. The following

general guidelines should also be considered.

Sensors height from Platforms, walk way/ decks, etc, A platform or walkway must be available for access to the

weather covers. The optimum condition would have the mounting flanges and weather covers approximately 5

feet up from the floor. Railings and other obstructions should allow the weather cover to swing clear as shown in

the installation drawings.

Locate the stack-mounted units in an area with ambient temperatures between -4 o to +130o F. (Consult the factory for

other temperature ranges.) Areas that are clean and dry are desirable. Avoid areas with condensation.

Maintenance intervals are directly related to the installation environment. Intervals can vary from 2 to 3 months in fairly

clean environments, to twice a

month in dirty environments. Lens

cleaning is a function of the

ambient conditions and cleanliness

of the purge air.

Locate the instrument to avoid

excessive vibration or shock.

Locate the control unit in an easily

accessible area with temperatures

between +32o to 122o F. To permit

the operator to read and/or change

controls, the unit should not be

mounted higher than five feet from

floor level.

Stack exit, Locate the transceiver

more than two stack diameters

down from the stack exit is

recommended.

19

INSTALLATION – MECHANICAL

A review of the drawings and procedures provided will help to produce an error free installation. However, there are

important additional points that must be observed. The beam of the instrument must be kept in the horizontal plane; the

transceiver cannot be rotated more than +/- 10 o from vertical. The weather covers must be installed vertically plumb.

Installation and wiring diagrams are found at the end of this manual. Please review all drawings prior to starting installation

or wiring. If you have any questions please contact our service department for assistance at 203-935-0102 ext. 14 or email

[email protected].

INSTALLATION PROCEDURE - STACK FLANGES

For an opacity monitor, the customer is required to supply and install two 3" I.P.S. flanges at eye level directly across from

each other. The flange faces, mounted on pipe stubs, should be approximately 6" to 8" from the stack or insulation. On

completion of the installation, the flanges must be aligned so that the total deviation of the light source flange relative to a

common centerline, does not exceed +1o and the retro reflector flange does not exceed +3o .

Flanges should be mounted approximately 5 feet up from the deck of platforms, roof or walk way.

At installations where conditions permit, this may be accomplished by using a piece of 2 1/2" pipe suspended across the

stack protruding far enough to allow slipping the 3" flange pipe assemblies over each end and welding in place as shown in

Drawing EMS1001.

Any deviation up to the previously specified limits can be adjusted out during the installation and alignment of the light

source and retro reflector with the system's alignment adjustments.

Where installations do not permit the use of the aforementioned method, the following procedure will accomplish the same

results. (See drawing EMS1002. An alignment tool can be purchased from the factory to insure accurate alignment.

1. Accurately locate one 3 1/2" diameter hole (large enough to accept the 3" pipe) and the other

hole approximately 1/2" diameter, directly across from each other. Attach the alignment tool to

the flange/pipe assembly and insert the pipe into the 3 1/2" hole in the stack wall. Align the

assembly with the 1/2" diameter hole on the opposite side by viewing through the alignment tool

and weld the pipe in place. Care must be exercised when welding to maintain alignment.

2. The 1/2" diameter hole should now be enlarged approximately 3 1/2" to accept the other

flange/pipe assembly. Proceed in the same manner, installing the assembly with the alignment

tool attached, and weld in place maintaining concentric alignment with the 3" pipe previously

installed on the opposite wall.

mailto:[email protected]?subject=Installation%20assistance

21

FLANGE MOUNTING UNDER AND OVER 6’ STACK

22

AIR PURGE/WEATHER COVER MECHANICAL INSTALLATION

23

MOUNTING THE AIR PLENUM AND WEATHER COVERS

WARNING! CONTROL UNIT, TRANSCEIVER & RETRO SERIAL

NUMBERS MUST MATCH.

After the installation site has been selected and the platform requirements have been met, the mounting flanges should be

installed and aligned. Flanges should be installed with the mounting faces on the vertical plane.

1) Before installing the Transceiver, Retro reflector or any type

of weather cover remove the air plenum from both the

Transceiver and retro reflector. Removal will make the

installation easier and less chance of damage while

mechanical attachment of the air plenums and optional

weather covers when provided.

2) If the transceiver and retro reflector have been shipped from

the factory with the air plenum attached, un-clip both hold

down latches, swing open and lift up & off the hinge pins.

Place the Transceiver and retro in a safe place.

3) The air plenum is attached to the customer supplied 3" pipe

flange by four 2 1/2" long 5/8-11 bolts. Working from the 3"

flange the correct assembly is; gasket then air plenum.

4) If you have weather covers remove the two (2)-weather cover hood hinge pins located on the

upper right and left hand corner of the hood. The air plenum and weather cover are attached to

the 3" pipe flange by four (4) 2 1/2" long 5/8-11 bolts. Working from the 3" flange the correct

assembly is; gasket, weather cover mounting plate, gasket, mating flange & air plenum. Place the

5/8-11 bolt through the top hole of the middle plate. Place a flat washer between the middle

plate and mating flange and pass the bolt through. Slip a split lock washer over the bolt and secure

with a nut. Repeat for the

remaining three mounting

bolts.

5) Any wiring or air hoses can

be connected now.

24

TRANSCEIVER AND RETRO REFLECTOR ASSEMBLY

6) Attach the Transceiver and Retro reflector to

the air plenum assembly by placing them on

the hinge pins.

7) Close transceiver & retro and secure in place

with the two hold down latches.

8) The air-purge blowers should be powered up

at this time to prevent stack particulate from

accumulating in the nipple and air-purge

housing.

Caution: If installed location has a positive pressure the air-purge system must be used continuously during installation to

prevent process gases from contaminating optical surfaces or over heating instrument electronics. If the system is shut off

for more than momentary interruptions, the instrument may be damaged. Failure to provide continuous air-purge may

void the warranty.

All wiring from the control unit to the transceiver should be completed at this time.

NOTE: THE AIR PLENUM ASSEMBLY FOR BOTH TRANSCEIVER AND RETRO MUST BE INSTALLED AS BELOW, I.E.

THE PINS ON THE LEFT SIDE POINTING UP!

26

BEAM ALIGNMENT PROCEDURE

Note: Alignment can not be done unless the power is applied to the stack mounted service module. The control unit does

not have to be connected or powered. For alignment accuracy, the stack should be at normal temperature.

NOTE: Alignment should be completed before instrument calibration. For alignment accuracy, the stack should be at

normal temperature.

1. If not already on, turn on the power to all air purge systems and service module.

2. Align the Reflector mating flange so it is plumb and parallel to the 3" 150# mounting flange. Use the 3 adjusting nuts on the air purge plenum flange until this is accomplished. The adjusting nuts have nylon locking inserts to prevent loosing by vibration.

Move to the Transceiver, and determine monitor alignment by looking through the viewing port located on the rear of the

transceiver and observing whether the beam image is in the center of the cross hair (bulls-eye).

Figure 2, Alignment of the transceiver

Adjusting bolts

27

SECTION 3 CONTROL UNIT (RCU) OPERATION PAGE DESCRIPTION

RCU UNIT BUTTONS

The arrows move left, right, up, down.

They are used to move display arrows or move to

other pages.

The ESC button is used to move back from the

page you are on to the previous page.

The enter or return button is used when

entering variable. Press it and the variable will change

from steady to blinking, enter the new value and

follow screen tip at the bottom to complete the

operation.

The info button is used for setting the PLC time,

date, back up, SD card functions, etc. This is not used

during normal operation. When required the use of the

functions will be explained in this manual.

The key pad is used to enter

values.

The +/- is used when (–) sign for values are

required.

These buttons are not used on this

model.

28

ABOUT PAGES

When power is first applied press ESC to display the Main page shown below.

Main page - By pushing UP or the DOWN arrow you can select the

EMS500 Display, Setup or About pages. Use the return/enter button to enter

the page (screen) you desire.

To get to the About page scroll down to About and press the right arrow button to

enter the 1st page of the about page.

29

Press the down arrow to get to the 2nd About page.

Note: Press “ESC” to go back on any page.

Press the down arrow to get to the 3rd About page

30

OPERATOR PAGES

The operator menu has a total of two pages with 7 set

points the operator can access.

By scrolling down the second menu screen is

displayed.

By pressing enter to select “Mode Select(Mg/OP)”

from the operator menu will display “active mode”

setting. Here is where you can select either Mg or

Opacity Mode.

Note: After this selection is made, alarm display

settings will reflect either opacity or Mg parameters.

31

By selecting alarm set point from the operator menu,

high opacity alarm set point can be entered.

By selecting alarm delay from the operator menu, the

alarm delay can be set. When the opacity reaches the

high alarm set point, this is the delay before the high

opacity alarm engages.

Early warning is a contact closure that engages when

the opacity reaches desired set point. This is used to

notify the operator before high opacity limit is

reaches.

Note: This contact is programmed with a fixed ten

second delay.

32

Press return/enter button to enter. Choose between 1-

auto or 2- manual.

Auto means, when the high opacity alarm has been

activated and when the level of smoke drops below the

alarm point the alarm contacts 02(high Opacity Alarm)

& 03(Opacity early warning) & 04(Boiler Shut Off) &

06(High Opacity Audible Alarm) will reset

automatically.

Manual reset means when the high opacity alarm has

been activated, pushing the return/enter button,

06(High Audible) contact will de-energize but 02(High

Opacity Alarm), 03(Opacity Early Warning), 04(Boiler

Shut Off) will remain energized. When the level of

smoke drops below the alarm point, the return/enter

button is pushed and 02, 03, 04, will be de-energized.

This is also true for the respective Mg relays, when Mg

is selected for “Active Mode”.

*NOTE: For the audible alarm contact to energize again,

the EW and High opacity need to be cleared after smoke

drops below alarm point.

By pressing F1 on this screen you can toggle if you

want to display tenths for opacity/Mg.

33

From this page, you can either accelerate or

decelerate the readings on the main display.

Note: only display will be affected.

PASSWORD PROTECTED TECH PAGES

To enter the “Tech” menu, press enter button and

enter the password 1234

Note: “Active Mode” display on top of the screen

represents what was selected from the first operator

screen. OP = Opacity, Mg = Milligrams.

Once password has been entered, the first tech menu

will be displayed.

34

To reach the second menu, move the curser down

until the second tech menu is displayed.

To reach the third tech menu keep bringing cursor

down until tech menu 3 is displayed.

By selecting output scaling from menu you can now

enter desired scale parameters for optical density,

Opacity, and Mg.

35

By selecting output scale OD from previous screen you

can now input parameters for Optical density 4-20mA

scale.

By selecting output scale OP from previous screen you

can now input parameters for Opacity 4-20mA scale.

When output scale Mg is pressed from previous

screen the 4-20 mA scale parameters can be inputted

here.

36

The output definition screen is where you can select

(for CH1 only) the desired output. Either Opacity or

Optical Density.

Select the desired unit of dust measurement from the

“active Unit” screen by selecting 1, 2, or 3.

The dust set – up screen is set to factory defaults, for

actual desired values, refer to the manual section 9

dust for description and tables.

37

In the OPLR setup screen, the stack exit I.D. and the

measurement path length I.D. Can be selected to

calculate OPLR.

NOTE: THIS SHOULD NOT BE DONE WITHOUT CONTACTING THE FACTORY FIRST.

For information purposes the flange to flange

dimensions are entered here.

Enter the Modbus network ID number on the screen.

38

To safely remove the SD card F1 needs to be pressed

first.

Cal preset values are entered here, 0% is entered for a

clear “cross stack” value, and 74% represents the span

N.D.F. inserted into the audit device to set the units

span value for linearity. Refer to “Clear Stack

Adjustment Procedure” in Section 6 of this manual

The Transceiver Display A screen will display the units

uncorrelated %Opacity, the internal parameters for

the LED current as well as the gain value.

39

Transceiver Display B will display the Transmittance as

well as the Uncorrelated % Opacity

40

SECTION 4 MODBUS

MODBUS SETUP

EMS500 Opacity Modbus Addresses MB = Modbus Poll Read Discrete inputs (10001….20000)

MI = Modbus Poll Read Holding (40001…50000)

Read:

Instantaneous Opacity MI 230 integer

OPLR Calculated MI 245 integer

High opacity alarm, Boiler shut off

MB 520 No alarm =0. Alarm =1

Early warning alarm MB 522 No alarm =0. Alarm =1

No Airflow MB 523 No alarm =0. Alarm =1

41

RS/485 COMMUNICATIONS AND CONNECTION

Port 2, 6-pin R J25 connector. Pin 1 (+), Pin 6 (-). RS-485 cabling may be up to 2000 feet in length. Belden P/N 3106A cable is

recommended. Note: Cable drawing and pin out at the end of drawing section.

If not specified in the original order default is as follows. NOTE: The following communication perimeters cannot be changed

in the field contact the factory.

Baud Rate 9600

Data Bits 8

Parity None

Flow Ctrl None

Timeout 0.2 seconds.

RS485: PIN OUT

Use RS485 to create a multi-drop network containing up to 32 devices.

Note: port #1is set to RS485

▪ Note that the ports are not isolated. If

controller is used with a non-isolated

external device, avoid potential voltage

that exceeds +/- 10V. To avoid damaging

the system, all non-isolating device ports

should relate to the same ground signal.

▪ Use shielded, twisted pair cables.

▪ Minimize the stub (drop) length leading from each device to the bus.

▪ Ideally, the main cable should be run in and out of the network device.

▪ Do not cross positive (A) and negative (B) signals. Positive terminals must be wired to positive and negative

terminals to negative.

43

SECTION 5 -OPTIONAL OUTPUT/RELAYS

CHANNEL #1 AND 2 FULL SCALE SET UP

(Maximum 500 ohm device load) Connect the (-) minus wire from your device to the bottom connector terminal 0V and the

(+) plus wire from your device to the terminal AO for channel 1 and AI for channel 2.

Note: Only CH1. Is selectable to either be %Opacity, or Optical Density. Ch 2. Is permanently designated as Mg only, and

is not selectable.

OPTIONAL ALARM RELAYS

Optional Alarm outputs are SPST relays. There are 2

groups each group has common See drawing EMS-1156

for connection details. Relays are rated at:

250Vac/30Vdc, 3Amp max per relay and 8Amp max per

common.

Group 2 Alarm Relay outputs:

04 - Boiler shut off 05 – Air Flow Alarm

06 – High Opacity Audible alarm

07 – High Mg Audible

COM to Group 2 only.

Set point and delay are chosen in the setup page. Choose Auto or manual mode in the setup page. For O2 and

O4 to be utilized as a boiler shut down you must select “Manual” in the alarm set up page.

Audible alarm and can be reset (acknowledged) even if the opacity is still above the set point.

Group 1 Alarm Relay outputs:

00 – Hi Mg/m3 Alarm

01 – Mg Early Warning

02 – High Opacity Alarm

03 – Opacity EW COM to Group 1 only.

44

Optional Analog outputs 4-20ma

The EMS500 comes with two 4-20mA output channels. The ranges are set during final test to the information supplied by

the customers. Field changes can be made in the set up page. Maximum output Loop compliance is 500 Ohms.

Channel 1: 0V & A0 can be used for DAS, recorder etc.

Channel 2: 0V & A1 can be used for DAS, recorder etc.

Optional Analog output wiring list wiring list

Bottom Connector

Common for mA outputs - 0V

Positive 4-20mA output CH1 - A0

Positive 4-20mA output CH2 - A1

4-20mA Outputs

45

SECTION 6 – CLEAR PATH ADJUSTMENTS

• clear condition across the monitor path length is needed

before adjustments can be made.

• Navigate to the Tech setup screen, when asked for

password enter 1234

• Scroll down to the Tech Menu 3 screen

• Scroll down to “cal preset values” and press

• Press to highlight the clear value and enter 0.00 or offset

desired.

• Press and hold for 2-3 seconds to store the clear value.

• Note: real time opacity is displayed in small numbers under

span value.

• System will be automatically linearized

Environmental Monitor Service, Inc. is available to assist you, call our service department at (203) 935-0102 or

Email: [email protected] for details and to schedule start up.

mailto:[email protected]

46

SECTION 7 - PREVENTIVE/CORRECTIVE MAINTENANCE

PREVENTIVE/CORRECTIVE MAINTENANCE SCHEDULE

ITEM TO CHECK FREQUENCY PROCEDURE

Projection lens and Reflector As required Clean with optical cloth and lens cleaning fluid

Beam alignment As required Check and adjust as necessary

Linearity check 3 months Adjust as necessary

Air filters 3 months Clean or replace as necessary

Air hoses 3 months Replace as necessary

Hose clamps 3 months Inspect and tighten

Mounting hardware 3 months Check bolts for tightness

Weather cover 3 months Clean as required

Cables and connectors 6 months Check, clean, replace as necessary.

Flange 6 months Push build-up into stack to clear flange

Clear stack or off stack zero Yearly Calibrate if necessary

Transceiver & Retro 3-5 years (site dependent) Return to the factory for internal optical

alignment and cleaning.

47

SECTION 8 - DRAWINGS

49

EMS-3203 ELECTRICAL WIRING CONNECTION

51

RECOMMENDED SPARE PARTS

Environmental Monitor Service Inc. PO Box 4340 Yalesville, CT 06492 Phone 203.935.0102 Email:

[email protected]

Digital systems Recommended Spare Parts 08/31/17 Startup of new system Recommended spare.

Serial numbers are required to insure order is correct.

Contact EMS for a customized quote for your facility. P/N DESCRIPTION

1 All system

1 per 4 inst. Or 1 per plant

3107 LED XT DP Source Assembly, serial number dependent.


1466 Transceiver/Retro reflector latch, spring & gasket repair kit.


2684 24VDC, 25W, 1A Output Din-Rail Mount Power Supply.

2 Recommended spares PS-1 and Procedure 3 requirements.


3193 SSM520 Assembly


2788 Opacity Portable off stack zero test kit.


3195 Zero reflector 19.8mm iris assembly with rotary solenoid, reflector tape and zero arm for Opacity Transceiver.


2935 Spare Retro Assembly Drop on pin type 3-15Ft. With aperture kit.

52

SECTION 9 DUST

CORRELATION WITH PARTICULATE/DUST DENSITY

According to Bouger's Law, the particulate or dust density contained within an optical path is directly proportional to the measured optical density of that path. The constant of proportionality differs with the gravimetric density of the particulate matter, its size distribution, and its optical properties. The constant can be calculated if all data is known. However, this is typically not the case. In practice, it is much easier to experimentally determine the proportionality constant and offsets for each installation. The data does not always correlate best with a line through the origin, that is, without offset.

The correlation coefficient and offset of the linear relationship between optical density and particulate density, typically mg/nM3, is determined from a linear regression analysis of a data set including simultaneous measurements of optical density and dust density. Such data should cover as large a range of operating variables as possible. Calibration, in terms of dust loading, is valid as long as the particle size distribution and composition do not change significantly. This condition is generally fulfilled in emissions from sources with high efficiency particulate control equipment.

To establish the accuracy of the calibration over a range of emission rates and process conditions, a large number of calibration points, at least 12 to 15, should be obtained by Method 5 or 17 Isokinetic. Then the regression line and associated confidence limits can be obtained. A substantial amount of data has been developed for correlating optical density with dust loading for a variety of applications. This data can be used as a starting point for characterizing any specific source. Figure 1 illustrates a calibration curve developed for a cement kiln equipped with an electrostatic precipitator. The 95% tolerance intervals at the 95% confidence level are indicated. Figure 2 shows the same calibration curve after correction to standard conditions (temperature and pressure including a dry basis. The corrected calibration curve can be used when gas temperature, pressure and water concentration are constant. Figure 3 shows a similar calibration curve obtained on a lignite-fired boiler, and Figure 4 shows a calibration curve for a bituminous coal fired power station.

Figure 1 Figure 2

53

Figure 3 Figure 4

54

Transmissometers have been used in numerous installations throughout the world for continuous monitoring of both opacity and particulate concentration, based on the correlations established between the optical density measurement and dust loading. In the dust monitoring applications the instrument calibration is typically checked by manual testing approximately once a year.

Table 1-1 summarizes the levels of error observed for different statistical analyses of a number of correlation lines for typical emission sources. Four different error definitions are shown. These error definitions are described more fully as follows:

a. Standard deviation expressed as the square root of the mean.

b. Type 1 error is the 95% confidence level that the true mean of all observed optical data for a given particulate concentration will lie within the limit.

c. Type 2 error is the 95% confidence level that the next one observation will fall within the limit.

d. Type 3 error is the 95% confidence level that 95% of all possible observations (95% tolerance) will fall within the limit.

Type 3 error specifications are typically applied in Europe, while the type 2 error definition is most common for US applications. The type 1 error yields the smallest errors, which range from 5 to 21% in the data.

55

The following correlation data available from different emission sources allows a comparison of stack opacities resulting from different emission sources at equal particulate concentrations and stack diameters. Some calculated opacities for a concentration of 150 mg/nM3 and a stack exit diameter of 10.12 ft (3M) are summarized in Table 1-2. Comparison of stack opacities for different emission sources under equalized conditions.

Table 1-2

56

From the lab results (Method 5 or 17 Isokinetic testing) draw a line from 0.0 to the point (OD,mg).

The graph can now be used to calibrate the monitor mg/m3 output and is valid until the user changes the source characteristics.

EXAMPLE AFTER THE STACK TEST

Use the values from the Lab test for the mg and the corresponding readings from the monitor for the OD (Optical Density) to plot the graph as above. The origin is 0.0 and the plot is a linear graph between the origin and the test results (OD, mg). Let us assume we had 300 mg/m3 and the corresponding OD = 0.125. Plot the graph and extend the line to about 3 time’s typical stack dust level. In this case 3 x 300 = 900 mg/m3 for the full scale.

EMS plot

0.000

0.125

0.375

0.0

100.0

200.0

300.0

400.0

500.0

600.0

700.0

800.0

900.0

0.000 0.100 0.200 0.300 0.400 0.500

O.D.

Con

cent

ratio

n (m

g/m

3)

Lo mg = 0 Hi mg = 900

Lo OD= 0 Hi OD = 0.375

4 mA = 0 20 mA = 900

57

READING RECORDED DATE FROM THE SD CARD

TO READ DATA FROM SD CARD, UNITRONICS SUITE PROGRAM MUST BE INSTALLED ON PC.

http://www.unitronics.com/

From Unitronics website select “PLC+HMI all – in - one”

Next select “software” then “Visilogic”

Scroll down and select “Download Software Utilities”

Select “SD Card Suite” and download.

READING DATA FROM SD CARD

• Insert SD Card to PC

• Locate SD Card on windows and open

• Select “DT” file

http://www.unitronics.com/

58

• Select “DT1” file

• Select “1 Minute”

• One minute data should now be displayed

VIEWING DATA IN EXCEL

• Select Export to CSV icon

• Create file name and save to desktop

ems500 opacity/dust monitor -...

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