envea STACK 602 User Manual
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envea STACK 602 User Manual

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STACK 602
USER MANUAL

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Summary of Contents for envea STACK 602

  • Page 1 STACK 602 USER MANUAL...
  • Page 3 STACK 602 Particulate Measurement System USER MANUAL Publication Part Number: PC-000848-MA...
  • Page 4 ENVEA UK Ltd. Disclaimer ENVEA reserves the right to revise and update this documentation from time to time without obligation to provide notification of such revision or change. Revised documentation may be obtainable from ENVEA.

  • Page 5: Table Of Contents

    STACK 602 Table of Contents Table of Contents ....................v List of Figures ....................vii INTRODUCTION ____________________________________________ 9 Purpose of this Manual ................9 Product Safety ..................9 1.2.1 Danger from Process ................. 9 Safety Procedures ................... 10 Intended Use ..................10 Additional Information................
  • Page 6 STACK 602 5.2.4 Setting up the Air Purges ..............29 Connecting the Transmitter (Tx) ..............29 5.3.1 Transmitter/Receiver Connections ............. 30 5.3.2 Transmitter/Receiver Link Settings ........... 30 Connecting the Receiver (Rx) ..............31 5.4.1 Data Cable Connection ..............32 Setting up the Receiver ................33 5.5.1 Bus Termination Switch (SW101) ............

  • Page 7: List Of Figures

    Recycling and Disposal of Electrical and Electronic Equipment ........ 64 INDEX ______________________________________________________ 65 List of Figures Figure 1: Dimensional drawing of STACK 602 sensor..........14 Figure 2: STACK 602 with 100 mm (4”) mounting stubs for high-temperature applications........................15 ® Figure 3: STACK 602 – DynamicOpacity Transceiver/Receiver.
  • Page 8 STACK 602 Figure 22: Opacity sensor test results (alternating)..........46 Figure 23: Dynamic Opacity sensor test results (alternating)......... 47 Figure 24: Maintenance Mode screen..............50 Figure 25: Placing sensor in Maintenance mode........... 50 Figure 26: Alignment principles – Transmitter............57 Figure 27: Alignment principles –...

  • Page 9: Introduction

    STACK 602 9 Maintenance Introduction Purpose of this Manual This manual contains all information necessary for the correct installation, setup, operation, and maintenance of the instrument. The procedures given in this manual must be carried out only by suitably trained and qualified personnel.

  • Page 10: Safety Procedures

    It may also invalidate the terms and conditions of the product warranty. Intended Use The STACK 602 particulate measurement sensor with DynamicOpacity ® technology is suitable for measurement in non-condensing applications, such as electrostatic precipitators (ESPs), boilers, calciners, and large-diameter emission stacks where dust levels are typically above 10 mg/m³...

  • Page 11: Additional Information

    Outer diameter PSU Repeater Power supply unit* Relay Output Module* Receiver (sensor head) Transmitter (sensor head) *ENVEA net module (see on page System Options 1.5.3 Related Documentation The following literature may be consulted in conjunction with this manual as applicable. A Reference Library with supporting information for your instrument is included with the product documentation.

  • Page 12: Product Parts And Options

    Product Parts and Options For details of product options, software, accessories, and spares for your instrument or system, consult the STAC 602 datasheet and order information available on request and from the ENVEA website (see a reverse of this manual). Certification 1.6.1 Conformance and related Standards ENVEA UK Ltd hereby declares that this instrument –...

  • Page 13: Technical Data

    Note: not recommended for deployment in applications with water droplets or mist at monitoring point. Inspection frequency Every 6 months (see page Sensor Specification STACK 602 Sensor Standard sensor 0–250 °C (up to 482 °F) (Tx/Rx): Sensor variants High-temperature 0–600 °C (up to 1,112 °F)

  • Page 14: Dimensioned Drawings - Sensor Heads (Tx, Rx)

    Requires optional air purge fitting and an external requirements supply of 30–60 l/min of dry, clean (oil-free) instrument air. Dimensioned Drawings – Sensor Heads (Tx, Rx) 2.2.1 Figure 1: Dimensional drawing of STACK 602 sensor. ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021)

  • Page 15: Quality Assurance And Control

    STACK 602 9 Maintenance Figure 2: STACK 602 with 100 mm (4”) mounting stubs for high-temperature applications. 2.2.2 Quality Assurance and Control Automatic and on demand Zero and Span Checks Frequency: alternating every hour (on a 2-hour cycle) 2.2.3 Sensor Options ▪...

  • Page 16: System Options

    System Options ▪ Standard Module (for single-channel systems) Control Unit ▪ ProController (for up to 32 sensors/channels) Network Modules (for use with ENVEA control units only) Analogue Output Module 8x 4-20mA (500Ω) (AOM) Auxiliary Input Module 4x 4-20mA inputs or 4x Digital inputs...

  • Page 17: Pc Software Suite (Pc-Me Dust Tools)

    ▪ Ethernet (RJ45; via Modbus TCP) ▪ USB 2.0 cable, standard type A-to-A, M:M PC-ME DUST TOOLS is supplied on a software CD and is Optical disc drive also available for download from the ENVEA website (DVD/CD) www.envea.global/s/process-en/dahs-software/pc- me-dust-tools/ ENVEA UK Ltd...

  • Page 18: Product Description

    The STACK 602 is designed to be compliant with TUV approved standards. The instrument is comparable and has the identical quality of measurement to its pre- decessor, the SC600T, which achieved both TUV QAL1 and MCERTS approvals.

  • Page 19: Control Unit

    STACK 602 9 Maintenance Automatic Self-Checks The instrument has automatic opacity Zero and Span checks (the latter simulating and therefore, effectively checking for contamination). The automatic self-checks monitor the integrity of the instrument daily. These checks simulate the operation of the instrument and permit any internal instrument problems to be self- detected.

  • Page 20: Principle Of Operation

    Figure 4: Principle of Operation – DynamicOpacity sensors. The STACK 602 measures the effect of particles on a light beam transmitted across the stack. The instrument measures the ratio of the temporal variation in intensity, unlike traditional opacity instruments, which simply measure the beam intensity.

  • Page 21: Unpacking And Preparation

    Carefully unpack the units and retain the packaging to return equipment for servicing or repair. If the equipment is damaged in any way, return it to ENVEA or your local ENVEA representative (for more information, see the reverse of this manual) in its original packaging.

  • Page 22: Cabling And Cable Routing

    The sensor may only be fitted to a metal duct or stack. If the stack is not metallic or you are concerned that the stack may not provide a suitably earthed shield for the sensor, please contact ENVEA.  It is recommended to use the grounding strap (or earth wire) to ensure the sensor body is firmly grounded to the metallic stack wall.

  • Page 23: Supplying Purge Air - Purge Blower Unit

    (see item 9, below). For more information and technical data, Figure 5 consult the small blower unit manual (see page All colour references are based on the standard ENVEA cables supplied. ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021)

  • Page 24: Connecting The Purge Blower

    [6] and wire it to the power supply terminal block as shown. Mains pin connections (L–R) Wire colour* Neutral Blue Protective Earth (GND) Green-Yellow Live Brown *All colour references are based on the standard ENVEA cables supplied. ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021)

  • Page 25: Adjusting The Speed

    STACK 602 9 Maintenance Figure 6: Purge blower wiring. 4.4.3 Adjusting the Speed The small purge blower unit has three speed settings: HIGH, MEDIUM, and LOW. ® The typical amount of purge air required for sensors is between DynamicOpacity 30 and 60 l/min under normal stack conditions (typically ±10 mbarg) to both the Transmitter and Receiver.

  • Page 26: Sensor Installation

    9 Maintenance STACK 602 Sensor Installation Safety Information WARNING! – DANGER FROM PROCESS It is possible that the sensors are to be installed in ducting containing process particulate that is hazardous to health. Unless the process conditions are known to be entirely safe, suitable...

  • Page 27: Assembling The Head Mounting Components (Tx/Rx)

    STACK 602 9 Maintenance 5.2.2 Assembling the Head Mounting Components (Tx/Rx) The STACK 602 is supplied with two stack mounting stubs ( ). The stack Figure 9 mounting stubs must be welded onto the stack in the chosen position. Then the sensor body (incl.

  • Page 28: Fitting The Stack Mounting Stubs

    9 Maintenance STACK 602 5.2.3 Fitting the Stack Mounting Stubs NOTE : Ensure adequate access is provided by ladder or staging to both the Transmitter and Receiver units, and sampling ports. When the stubs' optimum position has been decided, the stubs should be welded into position onto the stack.

  • Page 29: Setting Up The Air Purges

    STACK 602 9 Maintenance 5.2.4 Setting up the Air Purges Air purges are normally fitted to the Transmitter and Receiver to minimise contamination of the lenses. These are supplied as a filter/regulator assembly correctly fitted to the Transmitter and Receiver units.

  • Page 30: Transmitter/Receiver Connections

    Link in middle position LK201 Reset Link OFF Transmitter (Tx) Brightness control ENABLE Link pins 1 and 2 Heater DISABLE Link ON All colour references are based on the standard ENVEA cables supplied. ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021)

  • Page 31: Connecting The Receiver (Rx)

    STACK 602 9 Maintenance Connecting the Receiver (Rx) CAUTION! Ensure the cabling is not connected to the control unit power during wiring. Refer to below for the location of the terminals. After installation of the Figure 13 sensor, make the comms and power connections as described in the below sections.

  • Page 32: Data Cable Connection

    (SCREEN). Before refitting the cover, configure the Receiver as outlined in section 0 below. All colour references are based on the standard ENVEA cables supplied. Connect the cable screen to the nearest earth stud.

  • Page 33: Setting Up The Receiver

    STACK 602 9 Maintenance Setting up the Receiver Refer to above for the location of the setup switches. Check that the Figure 13 Tx/Rx link connections are set correctly. Refer to the table in section above 5.3.2 for details on links and on page above, resp., for the...

  • Page 34: Set Comms Settings (Sw200)

    Set the address DIP switch as required (see the following table). ASCII Figure 14: Basic setup – Communications settings. The Comms mode is set by ENVEA prior to installation and should be checked during the system installation. ENVEA UK Ltd...

  • Page 35: Basic System Setup

    STACK 602 9 Maintenance Basic System Setup This section provides information on the initial setup and operation of the ENVEA control unit. The same procedure applies to both the Standard Controller (Standard systems) ProController (PRO systems). advanced configuration, refer relevant...

  • Page 36: The Standard Controller Ui

    9 Maintenance STACK 602 Green = ON Switch ON power. POWER LED [Status] Off = No power Red (flashing) = alarm Switch ON power. ALARM LED [Status] Off = no alarm 6.1.2 The Standard Controller UI See below the UI layout of the Standard Controller showing the location of the user controls and Alarm/Power indicators.

  • Page 37: Procontroller - Function Keys And Setup

    STACK 602 9 Maintenance ProController – Function Keys and Setup Refer to the table below for details on operating and setting the function keys for quick access to frequently viewed screens. Symbol Meaning Action Displays the current top-level menu icon (for example, Setup, as shown).

  • Page 38: Other Symbols

    9 Maintenance STACK 602 Main menus Screen Description Displays logged or real-time data per DATA GRAPH sensor as line graph; log type and time (span) are selectable. Provides access to self-check screens, QUALITY ASSURANCE / calibration, maintenance, and enables SELF-TESTS running sensor checks manually.

  • Page 39: Initial Setup

    7.2.2 7.2.1 Checking the Comms Mode The Comms mode is set by ENVEA prior to installation and should have been checked during the system installation. 1. Open the main Setup menu screen. 2. Select Other Functions | Advanced Functions.

  • Page 40: Adding Sensors

    9 Maintenance STACK 602 Adding Sensors Sensor channels can be added to the control unit manually or automatically by using the Autodetect functionality. NOTE : The manual method should only be used to add sensors when manual control of the order in which the devices are displayed is required or only specific sensors are to be added.

  • Page 41: Editing Basic Sensor Settings

    STACK 602 9 Maintenance Editing Basic Sensor Settings When Autodetect is complete, a configuration button for each detected channel (up to six) is displayed on the Sensor Setup page. Figure 19: Main Setup screen.  Advanced settings and additional sensors are accessed through the More Settings menu.

  • Page 42: Sensor Channels

    9 Maintenance STACK 602 7.4.1 Sensor Channels For each STACK 602 sensor, the following channels are added to the control unit automatically. Switch to the Multiple Devices screen to view these. Channel Description Dust Dynamic opacity reading (can be calibrated in mg/m³)

  • Page 43: Adjusting Brightness And Sensitivity Manually

    STACK 602 9 Maintenance 3. Repeat the process for brightness: use the ^ / (Up/Down) controls to increase the Brightness % from 50% up to 100% until a reading of 80 is displayed (on the bar chart). 4. When finished, a confirmation message is displayed (Setup Complete).

  • Page 44: Calibration Factor (Cal Factor)

    9 Maintenance STACK 602 2. Increase the Sensitivity from Low → Medium → High, until a signal >12.5 is reached. Each sensitivity change will increase the reading by a factor of 8. 3. Increase the Brightness % from 50% (up to max. 100%), ideally to reach a level of between 80 and 100.

  • Page 45: Quality Assurance And Self-Tests

    STACK 602 9 Maintenance Quality Assurance and Self-Tests Available Sensor Tests The control unit provides the maintenance and testing functions outlined below. Function Purpose Maintenance Mode Puts the sensor heads in maintenance mode, allowing (Start/Stop) cleaning and maintenance of the sensor.

  • Page 46: Opacity Self-Tests

    9 Maintenance STACK 602 Opacity Self-Tests 8.2.1 Viewing Opacity Self-Tests 1. Open the QA/Self-Tests menu screen, then select Device | Stackn Opacity to display the self-test results for a sensor (see below): Figure 22 1a. Light Normal: displays the current level of scintillation at the Receiver.

  • Page 47: Dynamic Opacity (Dust) Self-Tests

    STACK 602 9 Maintenance Dynamic Opacity (Dust) Self-Tests ® 8.3.1 About DynamicOpacity Self-Tests The numerical values displayed on the ‘Dust’ (Dynamic Opacity) QA/Self Tests page (see below) are all measures of raw scintillation counts. Raw Figure 23 scintillation is the amount of light signal variation seen at the Receiver due to the dust flow.

  • Page 48: Setting Sensor Tests And Alarms

    9 Maintenance STACK 602 at a frequency within the measurement band of the instrument. An expected reading from this test is around 200,000. Example: referring to above, the result shows a Light Normal Figure 23 scintillation count of 463 just before the test, which increases to 273,800 during the test.

  • Page 49: Maintenance

    STACK 602 9 Maintenance Maintenance Safety Information CAUTION! Refer all servicing or maintenance to qualified service personnel. WARNING! – HAZARDOUS VOLTAGES This equipment contains lethal voltages! Always switch OFF and isolate the unit from the power supply before removing the front cover.

  • Page 50: Placing A Sensor In Maintenance Mode

    9 Maintenance STACK 602 9.2.1 Placing a Sensor in Maintenance Mode 1. Select Setup | Other Functions | Maintenance Mode to display the following screen. Figure 24: Maintenance Mode screen. 1a. To put all sensors into Maintenance mode: select Start Maintenance (All Devices).

  • Page 51: Service Messages

    Action required installation Remove the sensor from the stack for Inspection due 6 months inspection and cleaning. Arrange service visit by an ENVEA Service Service due 12 months Engineer or an authorised ENVEA representative. Major Service Recommended return to ENVEA for testing 4 years and refurbishment if required.

  • Page 52: Inspecting And Cleaning Procedures

    9 Maintenance STACK 602 Inspecting and Cleaning Procedures The nature of many processes is such that a build-up of particulate may develop on the sensor windows. This build-up will normally not affect the instrument's performance, but it is recommended that the build-up is periodically removed. Put the sensor in Maintenance mode (see page ).

  • Page 53: Checking Spurs

    STACK 602 9 Maintenance Solution: if the problem exists with one or two devices, visit those devices and check: 4. Cable connections 5. Comms DIP switch settings 6. Network address DIP switch settings 7. Bus termination setting. NOTE : To prevent bus conflicts, each sensor/device must have a unique address. Devices must not use address ‘0’.

  • Page 54: Frozen Readings

    ‘Light Normal’ level has dropped significantly If this does not resolve the problem, please below the setup level contact ENVEA or your local ENVEA representative. See section below for likely cause (Step 2a) 9.5.8 and instructions on how to resolve this issue.
  • Page 55 STACK 602 9 Maintenance 2a. The Received Light level is saturating the Rx (level fixed at 118): in this case, no scintillation (SC) signal will be generated, and so the dust reading is zero. 2b. The sensor has become misaligned, and the Received Light level at the Rx is very low (level fixed at <1): in this case, the ‘Dust’...

  • Page 57: Appendix A - Alignment

    Receiver), the light level at the Receiver will be reduced. Figure 26: Alignment principles – Transmitter. Receiver (Rx) The STACK 602 Receiver consists of a lens that focuses the received light onto a small Receiver diode (see below).

  • Page 58: Alignment Procedure

    Appendix A – Alignment STACK 602 Figure 27: Alignment principles – Receiver. Alignment Procedure Aligning the Sensor Heads using the Alignment Tool An alignment tool ( ) is provided that simulates the effect of the lens and Figure 28 Receiver diode.

  • Page 59: Figure 29: Aligning The Receiver (Rotated View)

    STACK 602 Appendix A – Alignment Observe the target to align the Receiver: the target centre represents the location of the Receiver diode. Figure 29: Aligning the Receiver (rotated view). 1. Referring to , adjust the bolts on the flange to get an image on the...
  • Page 60 Appendix A – Alignment STACK 602 4. Adjust the reading by manually turning bolts B and C slowly clockwise until the maximum possible reading is reached. (Note that the reading will go up when turning the bolts clockwise; however, turning them too far will cause the reading to go down again.)

  • Page 61: Appendix B - Calibration

    Appendix B – Calibration Introduction STACK 602 sensors attached to the control unit can be calibrated in mg/m³ in certain applications. Calibration is carried out with reference to an isokinetic sample (manual stack method). The isokinetic sample should be carried out to the relevant standards as defined by your local environmental authority or government agency.

  • Page 62: Using The Calibration Tool

    Appendix A – Alignment STACK 602 6. Enter the New Cal Factor (as described below). Entering a new Cal Factor 1. Select Setup | More Settings | Edit an Existing Device. 2. Select the Device to be edited and enter the Cal Factor value.

  • Page 63: Figure 31: Calculating The Calibration Factor Automatically

    STACK 602 Appendix A – Alignment Calculating the Calibration Factor: Manual Method The Calibration (Cal) Factor can then be calculated manually or automatically using the control unit calibration tool. Calculate the Calibration Factor manually 1. Record the Sensor Average. 2. Obtain the isokinetic sampling test result.

  • Page 64: General Notices

    General Notices STACK 602 General Notices List of Materials The following tables provide a list of materials used in the construction of this product. Material Where used Standard sensors (0–250 °C) 316 Stainless Steel Sensor rod and body Aluminium alloy...

  • Page 65: Index

    STACK 602 Index Index principles of operation · 20 process danger from · 9 product marking · 9 abbreviations · 11 disposal (of electronic equipment) symbols on · 9 adding · 64 product safety · 9 PSU Repeaters · 53 distance protective earth ·...
  • Page 66 Index STACK 602 PCB (Tx, Rx) · 42 analogue outputs · 44 problems · See power loss Autoset function · 42 radiating · 21 transmitter (Tx) · 11 calibration tool · 62 control unit · See alignment troubleshooting · 52 Modbus outputs ·...
  • Page 68 ENVEA UK Ltd, part of the ENVEA Group (France), supports distribution and service partners worldwide where teams of ENVEA Sales and Service engineers are available to consult regarding equipment suitability and technical support. To find a local ENVEA representative for your country or region, please contact us or visit our website at www.envea.global...

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