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]
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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
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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.
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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.
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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.
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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.
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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.
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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)
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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.
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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
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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).
2. Straight vertical
section of stack or
duct
Less than 4 equivalent
diameters upstream from a
bend
In the plane defined by the downstream bend (see figure 1–2).
3. Straight vertical
section of stack or
duct
Less than 4 equivalent
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
diameters downstream from
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
Less than 4 equivalent
diameters downstream from
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).
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(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.
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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
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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.
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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
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.
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FLANGE MOUNTING UNDER AND OVER 6’ STACK
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AIR PURGE/WEATHER COVER MECHANICAL INSTALLATION
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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.
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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!
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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
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Transceiver Display B will display the Transmittance as
well as the Uncorrelated % Opacity
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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
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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.
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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.
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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
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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.
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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.
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SECTION 8 - DRAWINGS
48
49
EMS-3203 ELECTRICAL WIRING CONNECTION
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RECOMMENDED SPARE PARTS
Environmental Monitor Service Inc. PO Box 4340 Yalesville, CT 06492 Phone 203.935.0102 Email:
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.
1 per 4 inst. Or 1 per plant
1466 Transceiver/Retro reflector latch, spring & gasket repair kit.
1 per 4 inst. Or 1 per plant
2684 24VDC, 25W, 1A Output Din-Rail Mount Power Supply.
2 Recommended spares PS-1 and Procedure 3 requirements.
10 per 4 inst. Or 1 per plant
3193 SSM520 Assembly
11 per 4 inst. Or 1 per plant
2788 Opacity Portable off stack zero test kit.
12 per 4 inst. Or 1 per plant
3195 Zero reflector 19.8mm iris assembly with rotary solenoid, reflector tape and zero arm for Opacity Transceiver.
13 per 4 inst. Or 1 per plant
2935 Spare Retro Assembly Drop on pin type 3-15Ft. With aperture kit.
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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
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Figure 3 Figure 4
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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.
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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
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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
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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
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• 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