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EMS 1304 Installation And Operation Manual

Opacity monitor
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E N V I R O N M E N T A L
M O N I T O R
S E R V I C E ,
I N C .
0 9 / 1 5 / 2 0 1 1 R E V - 1 6
Model 1304 Installation and Operation
Manual
 Environmental Monitor Service, Inc.
• PO BOX 4340
Yalesville, CT 06492
Phone 203.935.0102 • Fax 203.634.6663
Sales@emsct.com
Prepared by: James F. Cognetta
0

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  • Page 1 S E R V I C E , I N C . 0 9 / 1 5 / 2 0 1 1 R E V - 1 6 Model 1304 Installation and Operation Manual  Environmental Monitor Service, Inc. • PO BOX 4340 Yalesville, CT 06492 Phone 203.935.0102 •...

  • Page 2: Guidelines For User Safety And Equipment Protection

    Ship to: ENVIRONMENTAL MONITOR SERVICE 87 Gypsy Lane Meriden, CT. 06450 Phone 203.935.0102 ext 14 Fax 203.634.6663 E-mail: service@emsct.com 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.
  • Page 3 1. Limited Warranty a) Warranty. Except as otherwise provided herein, Seller warrants to Buyer that the Products sold to Buyer are, at the time of shipment to Buyer from Seller, free from defects in material and workmanship. ii) This warranty shall be valid for a period of twelve (12) months from the date of shipment to Buyer, unless a different period is specified herein, or in Seller’s applicable price list in which case the specified period shall apply.
  • Page 4 e) Software and Firmware Products. The sole and exclusive warranty applicable to software and firmware products provided by Seller for use with a processor will be as follows: Seller warrants that such software and firmware will conform to Seller's program manuals current at the time of shipment to Buyer when properly installed on that processor, provided however that Seller does not warrant that the operation of the processor or software or firmware will be uninterrupted or error-free.

  • Page 5: Table Of Contents

    Normal mode of operation Instrument operations and adjustments Internal calibration system, zero mode 10 Internal calibration system, Span mode10 Overview of the systems operation 1304 Opacity Specifications Front Panel LED's Fault Messages Installation Considerations Control unit manual controls Choose an installation site...
  • Page 6 EMS 1002 - Mounting over 6’ stack 46 EMS 1024 - Air purge/Weather cover mech Installation EMS 1078 - PANEL cut out for 1304 control unit EMS 1079 -1304 control unit dimensions EMS 1077 - Terminal identification 1304 control unit...

  • Page 7: Warrantee Registration

    WARRANTEE REGISTRATION Read this manual before attempting installation! Information contained in this manual is subject to change without notice and does not represent a NOTICE: commitment on the part of Environmental Monitor Service, Inc. Environmental Monitor Service, Inc. reserves the right to make changes in the construction, design, specifications, and/or procedures that may not be reflected in this manual.

  • Page 8: Customer Service

    Customer service We strive to provide efficient and expedient service when an instrument or component is returned for repair. Your assistance can help us to better provide the service you need. To assure that we process your factory repairs and returned goods efficiently and expeditiously, we need your help. Before you ship any equipment to our factory please call our Service Response Center at 1-800-864-2814.

  • Page 9: Claims For Damaged Shipments

    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...

  • Page 10: System Description

    Transmissometer/retro reflector The Model 1304 is a precision, double-pass, dual beam Transmissometer that consists of a transceiver (transmitter/receiver) mounted on one side of a stack or duct and a passive reflector mounted on the opposite side. The light source, photo detectors, and all measurement/reference optics used in opacity measurement are housed in the transceiver.

  • Page 11: Principle Of Operation

    PRINCIPLE OF OPERATION Normal mode of operation The Dual beam measurement system has a stack mounted Transmissometer sensor system consists 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 (See Drawing) 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.
  • Page 12 TTL Bulls-eye Projection Lens Retro Reflector Aperture P Span Filter Main Lamp Aperture V Zero Reflector Span Filter out: Span Filter in: Zero Reflector out: Zero Reflector in:...

  • Page 13: 1304 Opacity Specifications

    1304 OPACITY SPECIFICATIONS Design and performance: Meets or Exceeds PS-1 Revised and ASTM D6216-03 Peak and Mean Spectral Response Photopic; 515 to 585 nm, less than 10% of peak response outside 400 to 700 nm Relative spectral response <10% Angle of View <...
  • Page 14 Enclosure NEMA 4 watertight enclosure Path Length 2 to 15 feet, 0.6 to 4.6 meters. Longer available Optical System Double Pass Light Source Aging Compensation Automatic Light Source Life > 5 years Ambient Temperature Limits to +131 F (-20 to +55 Process Gas Up to 750 F (400...

  • Page 15: Installation Considerations

    INSTALLATION CONSIDERATIONS Choose an installation site The primary considerations for choosing a site for the Model 1304 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.

  • Page 16: Alignment Of Stack Flanges 15 S E

    Alignment of stack flanges Stack flange alignment is shown on Drawing EMS-1001 and EMS 1002, and is the first step in successful installation. The final beam alignment adjustments are described in the Beam Alignment Procedure. Installation procedure - stack flanges For an opacity monitor, the customer is required to supply and install two 3"...

  • Page 17: Reading Analog Output Block Addresses:16

    Reading Analog output Block Addresses: 0% to 100% instantaneous opacity = 40150 (integer) (xx.xx), 0% to 100% average opacity = 40151 (integer) (xx.xx), 0 to 10% Window Dust = 40073 (integer) (x.xx) Reading Discrete output Block Addresses: Relay 1- Cal in progress, duration 6 minutes (0 = cal, 1 = cal) Relay 2- High opacity alarm (0= Alarm, 1= Alarm) Note: always 0 during cal cycle.

  • Page 18: Changing Communication Settings

    Changing communication settings: Press EDIT (ESC) button, Scroll down EDIT  to COM MENU, press ENTER, at COM PORT press ENTER set to 1 for Modbus then press EDIT (ESC) button it will return to COM Port. (Note: controllers will automatically choose Modbus when the RS 232 port is not in use.) Press the EDIT ...

  • Page 19: Mounting The Air Plenum And Weather Covers

    After the installation site has been selected and the platform requirements have been met, the mounting flanges should be installed and aligned as described on Drawings EMS - 1001 and EMS - 1002. Flanges should be installed with the mounting faces on the vertical plane.

  • Page 20: Transceiver And Retro Reflector Assembly

    Transceiver and retro reflector assembly Attach the Transceiver and Retro reflector to the air plenum assembly by placing them on the hinge pins. Close transceiver & retro and secure in place with the two hold down latches. The air-purge blowers should be powered up at this time to prevent stack particulate from accumulating in the nipple and air-purge housing.
  • Page 21 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.

  • Page 22: Air Flow Switch

    Air flow switch If you have an airflow alarm when the system is powered check the airflow switch. With the blower running and the source under normal conditions disconnect the leads of the switch and place an ohmmeter across them. The switch should be closed, less than 2 ohms, if flow is enough to over come stack pressure and blower inlet is clear.

  • Page 23: C T I O N

    Section 3 BEFORE START UP You must complete the following before start up is attempted. Measure and record flange -to-flange distance to verify it is the same as final check out sheet. If you are using a recorder, DAS, etc., Outputs and inputs from DO NOT CONNECT THEM NOW.

  • Page 24: Start Up Service

    START UP SERVICE Environmental Monitor Service, Inc. is available to assist you, call our service department at (203) 935-0102 or fax (203) 634-6663 for details and to schedule start up. Verifying instrument operation and configuration Alignment procedure must be completed as outlined in Section 2. Power applied to both the control unit and the sensors for a minimum of 30 Minutes before any adjustments are attempted.

  • Page 25: Zero/Span Calibration Check

    ZERO/SPAN CALIBRATION CHECK The zero calibration has been set at the factory by placing the instrument on an optical bench using the flange-to- flange dimensions specified by the customer and recorded in the customers final test report. This zero value is critical as it can offset smoke measurement plus or minus if not correctly set.

  • Page 26: C T I O N

    Overview of the systems operation The Model 1304 Opacity monitor system consists of transceiver, retro reflector, service module and the control unit. The maintenance module has a digital display for reading opacity from the control unit and T 2 from the transceiver.

  • Page 27: Control Unit Manual Controls

    Control unit manual controls - Acknowledges fault alarms and displays the fault message. - Changes display each time it is pressed; Opacity %, Average Opacity, dust/zero shift, hours to next cal. - initiates a maintenance cal cycle and resets calibration cycle timer clock. AUTO/MAN Alarm set point adjustments Under the flip down door, press the EDIT (ESC) button (the red Edit...

  • Page 28: 4-20Ma Outputs

    4-20mA outputs Reference Drawing # 1131 The Model EMS1304 comes with two 4-20mA outputs. The ranges are set during final test to the information supplied by the customers. Maximum output Loop compliance is 800 Ohms. AOUT1 (instantaneous opacity, zero/span when in check mode) is connected at Control unit terminals 11 & 12 and supplies the opacity signal to a recorder or DAS and too the service module 14 &...

  • Page 29: Auto Cal Timer Adjustment

    Auto cal timer Adjustment Under the flip down door, press the EDIT (ESC) button (the red Edit (ESC) LED will light). The message display will read QUICK MENU. Press the ENTER key, then the EDIT  key 3 times or scroll down until the Display reads AUTOCAL CYCL TMR.
  • Page 30 Service module The service module is used to pass signals to and from the transceiver and control unit, display opacity via digital meter, initiate maintenance zero and span cycles and insertion of external current meter in the transceiver to control unit 4-20mA loop. OPACITY / T2 - This switch selects the display of the stack digital meter.

  • Page 31: C T I O N

    Do not attempt these adjustments in inclement weather. After the cover is removed from the transceiver normal levels of day light in the area will not effect the calibration. To complete this procedure the following items are required: EMS Micro-turn 200 on-line test kit (p/n 1232) with a high filter of at least 0.8 O.D.

  • Page 32: Span Filter Value

    Place the Opacity/ T 2 switch on the service module in the Opacity position to observe the correlated opacity on the digital display. Swing open the transceiver and initiate a zero with the zero switch on the service module to raise the zero reflector into place.

  • Page 33: Off Stack Zero Calibration

    11 inches compensates for air plenum spacing, as the air plenums are not used for the off stack zero calibration. If EMS test stands are not available, an alternate method is to use 3" pipe flanges with air plenums installed, contact the factory for air plenum availability. Set the spacing between the 3"...

  • Page 34: C T I O N

    "course" adjustment section of this manual. Figure 5, Micro-Turn 200 Place the EMS Neutral Density Slides in the slot provided on the top of the device just behind the mounting screw. The system should read the same value written on the label +/- 2% or better.
  • Page 35   Filter re-calibration is available from EMS and if not regulated by EPA regulations in your State to a more frequent schedule we suggest you re-calibrate at the minimum of once a year. If you have filters from other manufacturers we can also calibrate them as well (call for pricing).

  • Page 36: Course Adjustments

    Course adjustments and you can not reach zero after you have turned the adjustment knob as far Opacity is below zero as it will go into the Micro-turn housing perform the following procedure: Hold the Micro-turn in your hand so you can see the iris and retro reflector. Turn the fine adjustment knob so that the iris is closed as far as it will go.

  • Page 37: Filter Certification

    Filter certification QA/QC testing by EMS of the filters at an interval of not more than 6 months is recommended. Filter certification, replacement or additional Neutral Density Filters are available from EMS. EMS Neutral Density Filters for Micro-turn 200 are calibrated on a Perkin-Elmer Lambda Series 6 / PECSS Spectrophotometer per Federal Environmental Protection Agency specifications.

  • Page 38: Preventive/Corrective Maintenance37

    Section 7 PREVENTIVE/CORRECTIVE MAINTENANCE Preventive/corrective maintenance schedule Daily: Check Zero/Span marks are within specification (+/- 2%) Check for fault conditions Monthly or as required: Clean transceiver and retro windows Check alignment, correct if necessary Check air filters replace if necessary Quarterly: All daily and monthly checks Perform COM Audit per EPA regulation 40 CFR, 60 App.
  • Page 39 Every 3-5 Years: EMS recommends periodical, depending on the severity of the sensor locations 3-5 years between overhaul of our opacity system to keep them working at their optimal level. Overhauls become necessary do to the fact that over time dust, out gassing of electronic parts, removing protective covers, etc., manifest itself as overall optics...
  • Page 40 The best check of semiconductor performance is actual operation of the instrument. Weather cover/blower preventive maintenance Periodically - Check and inspect all hoses and wire connections inside the weather covers. Air Filter - Remove and inspect replace the filter cartridge as necessary. EMS p/n 2122...

  • Page 41: Trouble Shooting

    Trouble Shooting Problem Possible Cause Remedy Control unit reads 100%, both bargraphs are Transceiver current loop Operate/test switch must be in blinking, Alarm LED is on, Fault message to the control unit is open Operate. T2 4-20mA lost/low, service module meter Check wiring for open from in T2 reads -20 or higher.

  • Page 42: Trouble Shooting -Continued

    Trouble shooting -continued Problem Possible Cause Remedy Maintenance Mode message Maintenance switch or Return all to operate or maintenance function is neutral positions and press ACK key to clear alarms. 1- Control unit zero/span key was pressed. 2- Service module zero/operate switch in zero, span/operate switch in span...

  • Page 43: Spare Parts

    8 Pack Air filter replacement element (ID 1.5 OD 4.5 HT 5.875 Black) 1 per plant 1232 Micro-turn 200 on-line test reflector kit for EMS 13xx transceivers with 3 Neutral Density filters in hard carrying case. LEVEL 2 1 per 4 inst. Or 1 per plant 2555 1304 CPU board 1 per 4 inst.
  • Page 44 Opacity test stands for series 13xx transceiver & retro 1 per plant 1078 EMS 3" pipe Flange Alignment tool 1 per plant 1073 1304/1303 control unit to service module 10' test cable Prices: For price and delivery Call 203.935.0102 ext 11, Fax 203.634.6663 or email service@emsct.com...

  • Page 45: Drawings

    Section 8 DRAWINGS...

  • Page 46: Ems 1001 - Mounting Under 6' Stack

    EMS 1001 - Mounting under 6‘ STACK...

  • Page 47: Ems 1002 - Mounting Over 6' Stack

    EMS 1002 - Mounting over 6’ stack...

  • Page 48: Ems 1024 - Air Purge/Weather Cover Mech Installation

    EMS 1024 - Air purge/Weather cover mech Installation...

  • Page 49: Ems 1078 - Panel Cut Out For 1304 Control Unit

    EMS 1078 - PANEL cut out for 1304 control unit...

  • Page 50: Ems 1079 -1304 Control Unit Dimensions

    EMS 1079 -1304 control unit dimensions...

  • Page 51: Ems 1077 - Terminal Identification 1304 Control Unit

    EMS 1077 - Terminal identification 1304 control unit...

  • Page 52: Ems 1131 -1304 With Recorder System Wiring

    EMS 1131 -1304 with recorder system wiring...

  • Page 53: Purge Blower Electrical And Pressure Information

    PURGE BLOWER ELECTRICAL AND PRESSURE INFORMATION Single Phase 110VAC 220VAC 50/60Hz 50/60Hz Start Amps Run Amps 4.5-5.7 2.2-2.8 H.P. Blower Performance Pressure...
  • Page 54 EMS1101 - Sht 1 of 3 Dual Blower system wiring...
  • Page 55 EMS 1101 - Sht 2 of 3 Single Blower system wiring...
  • Page 56 EMS 1101 - Sht 3 of 3 Without Blower system wiring...

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