operation and maintenance manual - ametek land · model 4500 mkii + dust and opacity monitor...

Operation and Maintenance Manual

Combustion & Environmental Monitoring

Model 4500 MkII+ Dust /Opacity MonitorPublication Nº 770-068

Language EnglishIssue 7 September 2012

Equipment OperationUse of this instrument in a manner not specified by Land Instruments International may be hazardous.

Electrical Power SupplyBefore working on the electrical connections all of the electrical power lines to the equipment must be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these operating instructions. If in doubt contact Land Instruments International.

Face and Eye ProtectionSuitable face and eye protection must be worn when working on hot vessels and ducts! Special safety measures must be taken when working on a high-pressure duct.

Protective ClothingProtective clothing must always be worn when working in the vicinity of hot vessels or ducts.

StorageThe instrument should be stored in its packaging, in a dry sheltered area.

UnpackingCheck all packages for external signs of damage. Check the contents against the packing note.

Return of Damaged Goods

IMPORTANTIf any item has been damaged in transit, this should be reported to the carrier and to the supplier immediately. Damage caused in transit is the responsibility of the carrier not the supplier.

DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save the packing with the damaged article for inspection by the carrier.

Return of Goods for RepairIf you need to return goods for repair please contact our Customer Service Department. They will be able to advise you on the correct returns procedure.

Any item returned to Land Instruments International should be adequately packaged to prevent damage during transit.

You must include a written report of the problem together with your own name and contact information, address, telephone number, email address etc.

Return of Goods for Repair Form is available for download from our websites.

Lifting InstructionsWhere items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the Technical Specification for weights. All lifting should be done as stated in local regulations.

Design and Manufacturing Standards

The Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for the design, manufacture and on-site servicing of combustion, environmental monitoring and non-contact temperature measuring instrumentation.

Approvals apply in the USA

This instrument complies with current European directives relating to Electromagnetic Compatibility 89/336/EEC and Low Voltage Directive 73/23/EEC.

Operation of radio transmitters, telephones or other electrical/electronic devices in close proximity to the equipment while the enclosure doors of the instrument or its peripherals are open, may cause interference and possible failure where the radiated emissions exceed the EMC directive.

The protection provided by both CE and IP classifications to this product may be invalidated if alterations or additions are made to the structural, electrical, mechanical or pneumatic parts of this system. Such changes may also invalidate the standard terms of warranty.

Dimensions Unless otherwise stated, all measurements are given in millimetres and inches.

Copyright

This manual is provided as an aid to owners of Land Instruments International’s products and contains information proprietary to Land Instruments International. This manual may not, in whole or part, be copied, or reproduced without the expressed written consent of Land Instruments International Ltd.

Copyright © 2007 - 2010 Land Instruments International.

Signs and Symbols Used onEquipment and Documentation

Observe precautions for handling electrostatic discharge sensitive devices.

Protective Conductor Terminal.

This item or material must be disposed of in accordance with the Waste Electrical and Electronic Equipment directive as applied by local regulations.

This item or material can be recycled.

Caution, hot surface.

Caution, attention to possibility of risk of damage to the product, process or surroundings. Refer to instruction manual.

Caution, risk of electric shock.This item or material can be recycled.

Office Locations

UK - DronfieldTel: +44 (0) 1246 417691E-Mail: [email protected]: www.landinst.com

USA - PittsburghAMETEK Land, Inc.Tel: +1 412 826 4444E-Mail: [email protected]: www.ametek-land.com

For further details on all LAND/Ametek offices, distributors and representatives, please visit our websites.

Important Health and Safety Information

IMPORTANT INFORMATION - PLEASE READ

REV 3 April 2004 Publication Number 770.068

Contents

A1 General Description 1

A2 System Summary 2

A3 Installation Equipment Requirements 3A3-1 Selecting an Installation Location 3A3-2 Defining the Installation Pathlength 7A3-3 Dimensional Information 7A3-4 Mounting Details 9

A4 Installation 11A4-1 Installation Checklist 11A4-2 Mounting Stand-offs 12A4-3 Mounting Transceiver and Retroreflector 15A4-4 Local Control Unit Installation 17

A5 Fail Safe Shutter 18

A6 Electrical Installation 19A6-1 Electrical Connections Overview 19A6-2 System Cables 21A6-3 Customer Connection Details to Termination Box 22A6-4 MODBUS Connections 23

Contents

B1 General Description 24

B2 Getting Started 26B2-1 The Control Panel 26B2-2 Function Keys 27B2-3 Glossary of Terms 28B2-4 Using the Instrument for the First Time 29

B3 Normal Modes of Operation 46B3-1 Alarm Setup 46B3-2 Output Setup 48B3-3 MODBUS Communications 53

B4 Periodic Modes of Operation 62B4-1 Calibration Check 62B4-2 Calibration Audit 63B4-3 Re-calibration 65B4-4 Isokinetic Calibration 66B4-5 M203 Clear Stack Simulator 70B4-6 M203 Clear Stack Simulator Calibration 75B4-7 Zero Point Reflector Adjustment 78B4-8 Upscale Span Filter Adjustment 82

Contents

C1 Theory of Operation and Application 85C1-1 General Outline 85C1-2 Beer-Lamberts Law 86C1-3 Optical Pathlength Ratio (OPLR) 87C1-4 Examples of Different Optical Path Length Correction Ratios (OPLR) 89

C2 Requirements for Environmental Legislation 90

C3 Physical Principles 91C3-1 General Description 91C3-2 Principle of Operation 92

C4 User Interface 94C4-1 Operational Structure 94C4-2 Faults Screens 95C4-3 Calibration Screens 96C4-4 Setup Screens 102C4-5 Display Screens 116C4-6 Parameter Screens 118

C5 System Specification 119C5-1 4500 MkII+ Dust and Opacity Monitor 119

C6 Testing and Checking 122C6-1 Identifying Faults 122C6-2 Maintenance 124C6-3 Replacement Parts and Consumables 128

C7 How to Get Further Assistance 133

C8 Configuration Record Sheet 134

Appendix A Aperture & Grating Selection Tables iAppA-1 Automatic Zero Point Reflector Aperture and Grating Selection iAppA-2 Span Filter Grating Selection i

Appendix B Low Temperature Termination Box iiAppB-1 Termination Box Heater Unit ii

1

Model 4500 MkII+ Dust and Opacity Monitor Operation and Maintenance Manual

A1 General Description

The Land Instruments International Model 4500 MkII+ Continuous Opacity Monitoring System (COMS)measures opacity by shining a light beam through flue gases. An internal microprocessor calculatesdust density and other parameters. The instrument comprises the following parts: The Transceiverwhich contains all of the electronic and electrooptic components; the Retro-Reflector containing acorner cube reflector; the Termination Box where the customer terminations are located; and the airpurge system. An optional data display Control Room Unit is available.

The air purge system can take several forms depending upon individual site requirements. Single anddual electric blowers are available, as are compressed-air driven devices. Continuous purge air supplyis essential to prevent dust and corrosive gases from affecting the optical system. Automatic failsafeshutters can also be fitted for temporary protection in the event of a purge air failure.

The entire system is designed for continuous operation in all weather conditions, with minimalmaintenance.

TerminationBox

Transceiver

Retro-Reflector


2

A2 System Summary

The Model 4500 MkII+ Dust Opacity Monitoring System comprises the following key components. Theuse of a Control Room Unit is optional. Weatherproof covers option not shown.

1 Model 4500 MkII+ Transceiver2 Model 4500 MkII+ Retroreflector3 Termination Box4 Air Blower with Filters5 Umbilical cable

Important

An external circuit breaker incorporating over-current protection or a power isolator and fusemust be fitted.

CAUTIONDANGER

1 2

3

5

6

9

7

8

4

10

6 Instrument Power Input7 Blower Pressure Switch Trip Output8 Blower Power Input9 External Power Isolator10 External Power Isolator with fuse


3

Measurement Area Platform

A3 Installation Equipment Requirements

A3-1 Selecting an Installation Location

IMPORTANT

Before fitting the mounting flanges consider the blower type and mounting.

The transmissometer should be mounted on the stack or duct so that it can detect a representativeconcentration of dust across the stack or duct diameter. For new plants, location of the transmissometershould be planned during the design stages; for existing plants, it is critical that the best possiblelocation be selected. If the monitor is to be used for US regulatory compliance, the location should bedetermined by the EPA installation specifications detailed in 40 CFR 60, Appendix B, Specification 1, ora location approved by the appropriate agency.

At the measurement location, there should be as much negative pressure as possible, for example, astack updraft. The mounting area must have a safe walkway; if necessary, a sufficiently large andaccessible platform should be constructed (see below).

Measurement errors may result if the transmissometer is exposed to strong vibrations or if the stack orduct changes shape as the gas temperature changes. If these are problems which cannot be avoided, avibration free mounting can be installed. Land Instruments International can providerecommendations for vibration free mountings upon request.

The ambient temperature at the mounting location must remain between -20°C and +55°C (-4°F and131°F). If necessary, heating, ventilation, or isolation should be used to ensure this temperature rangeis not exceeded.


4

Installation Site Requirements Model 4500 MkII+

Installation Dimensions for Instrument

1. Transceiver2. Retroreflector3. Purge air entry4. Umbilical connector5. Flange to flange pathlength6. Transceiver open for calibration audit7. Retroreflector open for inspection

IMPORTANT Mounting Guidelines

1. The Transceiver (1) requires approximately 500mm (20) minimum distance for installation.2. The Retroreflector requires approximately 320mm (13) minimum distance for installation.3. Additional clearance is required of approximately 1m (39) for mounting and removal procedures.4. A minimum clearance of 150 mm (6") directly below the instrument is required for purge air and

electrical connections.5. The maximum recommended air hose length between the blower and the air purge is 7m (23ft).

Do not exceed this when installing the blower unit(s).6. The Termination Box must be mounted within 2m (79) of the Transceiver in order for the

interconnecting cable (4) to reach. Supplied by LAND Instruments International.7. Measurement Pathlength (5) is factory set and cannot be changed by the user.8. The Transceiver casing swings open (6), requiring a minimum of 340mm (14) to the left hand

side of the instrument.9. The Retroreflector casing also swings open (7), requiring a minimum of 160mm (7) to the left

hand side of the instrument.10. IMPORTANT: Ensure that the interconnecting cable has sufficient slack to enable the Transceiver

to be swung open.

3

520 (20.5) 240 (10) 320 (13)

220

(9)

15

0 (6

)2

20

(9)

240 (10) 1000 (39)

34

1000 (39)

580 (23)

42

0 (

16.

5)

6

500 (20)

160

(7

)

15

0 (6

)

5

1 2

7

220 (9) 220 (9)

Operation and Maintenance Manual Model 4500 MkII+ Dust and Opacity Monitor

5

Blank

Obsolete content removed


6

Installation Site Requirements Model 4500 MkII+ with Weatherproof Covers

800 (32)

730

(29)

2

1000 (39)

730

(29)

800 (32) 1000 (39)

800 (32) 800 (32)660 (26)

900

(35)

5

4

31 2 2 1

Installation Dimensions for Instrument with Weatherproof Covers

1. Weatherproof covers2. Air purge entry3. Umbilical connector4. Flange to flange pathlength5. Weatherproof covers projection

IMPORTANT Mounting Guidelines

1. The weatherproof covers require approximately 800mm (32) minimum distance forinstallation on either side of the stack.

2. The weatherproof covers require an additional 1m (39) approximately, for mounting andremoval procedures.

3. The Termination Box must be mounted within 2m (79) of the Transceiver in order for theinterconnecting cable (4) to reach. Supplied by LAND Instruments International.

4. Measurement Pathlength is factory set (requirement of EPA certification in the US) andcannot be changed by the user.

5. The weatherproof covers require a minimum of 800mm (32) to either side in order to swing openthe covers.

6. IMPORTANT: Ensure that the interconnecting cable has sufficient slack to enable the Transceiverto be swung open.


7

A3-2 Defining the Installation Pathlength

The installation pathlength is defined as the distance between the Transceiver air purge flange and theRetroreflector air purge flange. This is referred to as the flange-to-flange pathlength.

IMPORTANT

It is important to set the instrument to the correct pathlength (during manufacture). Failureto do so will affect the accuracy of the measurement readings.

Flange-to-Flange Path Length

A3-3 Dimensional Information

Dimensions of Model 4500 MkII+ Dust and Opacity MonitorWeight: Transceiver - 15.2 kg (33.5 lb); Retroreflector - 7.6 kg (16.8 lb)Dimensions of Model 4500 MkII Dust and Opacity Monitor with Fail-safe Shutters

Weight (with fail-safe shutters): Transceiver - 19.2 kg (42 lb); Retroreflector - 11.6 kg (25.5 lb)

250.0 (9.8) 270.0 (10.6)

220.

0 (9

.0)

270.0 (10.6) 50.0 (2.0)

220.

0 (9

.0)

255.

0 (1

0.0)

250.0 (9.8) 388.0 (15.3) 388.0 (15.3) 50.0 (2.0)

220.

0 (9

.0)

220.

0 (8

.7)

255.

0 (1

0.0)


8

Blank

Obsolete content removed


9

A3-4 Mounting Details

Air Purge Mounting Holes

The air purge unit must be fixed to the mounting flange. It has three mounting holes to accept themounting studs from the Standpipe.

ø190 (7.50)

Front view of Air Purge showing mounting holes

3 Holes as shown.Dia. 15 on 150.0/5.90 p.c.d.


10

Stand-off Flange

This assembly is made up of a mounting flange (specially adapted 3" ANSI) attached to a sleeve (stand-off), which is used to mount the instruments on the duct. Where required, lengthen or shorten the sleeveto obtain the appropriate measurement pathlength. Unstable mounting bases (such as thin sheet metalwalls) may require supplemental reinforcement. See next page for reinforcement detail.

Stand-off Flange Assembly (Part Number 702.790)

Stand-off Flange Reinforcement

1. Optional Reinforcement (Customer supplied)

Stand-off flange with reinforcement

NoteBefore installing mounting flanges, refer also to the Blower installation manual.

1

3 Holes as shown.Dia. 15 on 150.0/5.90 p.c.d.


11

A4 Installation

A4-1 Installation Checklist

In order to complete a full installation, check all the listed activities have been undertaken.

Selection of installation locationInstallation of mounting flanges

CAUTION

Apply purge air before installation ofTransceiver and Retroreflector

Installation of air blower system - refer to blowerinstrction manualConnection of purge air supplies to instrumentRouting all cablesElectrical connection of air blower systemElectrical connections for instruments andTermination BoxPower up air purge system

Connections for control room unit (optional) or anyother output devices to Termination Box (i.e. chartrecorder, display unit etc.)

Check continuity of protective earth

Application of purge air followed by installation ofthe Transceiver and Retroreflector units

Power up instrument and calibrate


12

A4-2 Mounting Stand-offs

The Model 4500 MkII+ is normally supplied with two mounting flanges with sleeves (stand-offs) whichare used to mount the transmissometer onto the stack or duct. The sleeves are 240mm (9.45") long.If necessary, shorten or lengthen the sleeves when mounting to obtain the proper measurement path.Unstable mounting bases, such as thin sheet metal walls, may require supplemental bracing (seeMounting Details section A5-4).

IMPORTANT

Stand-off mounting may be affected by the type of air purge blower unit to be used. Pleaserefer to the installation of blower units for further detail (see section A7).

The stand-offs must be mounted so that the Transceiver directly faces the Retroreflector across thecentre of the stack or duct. Since most applications involve a vertical stack, the axis common to bothflanges must be level or perpendicular to the direction of gas flow. The flange faces must be parallel towithin ±1°.

Accurately mark the centre of each stand-off flange on the stack and punch a locating mark throughthe liner onto the inner stack plating. Cut a hole from the liner large enough to allow eventual welding ofthe flange stub to the stack. Then cut a hole through the stack plate material at the punched locationmark on the Transceiver unit side of the stack. A 6mm to 12mm (0.25" to 0.50") pilot hole at theRetroreflector locating mark can also be cut at this time.

Ensure that the TOP label is in the 12 o'clock position and tack weld the Transceiver stand-off intoplace. The stand-off flange must be parallel to the stack wall. Care must be taken at this stage, orsubsequent instrument alignment may be impossible.

Mounting stand-offs with reinforcement

TOP


13

Cut a hole around the Retroreflector pilot hole, large enough to allow eventual welding of the outside ofthe flange stub to the stack wall. The mounting flange plate must be parallel to the stack wall.

IMPORTANT

The Model 4500 MkII+ Dust/Opacity Monitor is factory set to the flange-to-flange measuringpath as specified by the customer at the time of order. This measurement is indicated onthe back of the Transceiver. During the welding and alignment procedures, be sure theflange-to-flange measurement path does not differ by more than ±1% from that specified onthe Transceiver.

If the measuring path is easily accessible and short enough, the flanges can be aligned with a straightpiece of tube. First slide the tube through both flanges. Then, ensuring the specified flange-to-flangemeasuring path is maintained to within ±1%, tack weld the Retroreflector stand-off flange in place.Make the necessary adjustments and weld the Transceiver stand-off flange in place. Finally, make anynecessary adjustments and fully weld the Retroreflector stand-off flange in place.

Mounting flange alignment

When the measurement length is too long to use an alignment pipe, Land Instruments International cansupply an optical flange alignment tool (Part number 702.787). Contact Land Instruments Internationalif this part is required.

Flange to flange pathlength

Alignment Tube


14

Flange Alignment Tool (Optional)

The flange alignment tool (Part number 702.787) consists of two plates which are mounted to theflanges. One plate supports a light source, and the other plate supports a small telescope with a circlein the centre. When the flanges are properly aligned, the light spot must be located in the centre of thiscircle (see below).

Light Source Alignment Circle

Flange alignment tool

The flange alignment tool is used as follows:

1. Remove the disc springs from the standpipe flange and store.2. Tack weld the flanges.3. Mount the flange alignment tool as shown above.4. Align flange number 1 and weld it into place.5. Reverse the flange alignment tool (switch components).6. Align flange number 2 and weld it into place.7. Replace the disc springs, observing correct orientation.

(each stud requires 6 pairs of disc springs).

During the welding and alignment procedures, be sure the flange-to-flange pathlength isaccurately maintained to within ±1% of that specified on the Transceiver.

Stand-off Flange 1Stand-off Flange 2

Light Source


15

A4-3 Mounting Transceiver and Retroreflector

1 This procedure is best performed when the process is not operating and the stack is cold.

2 If the process is operating, and especially if the stack pressure is above atmospheric, the airpurge system should be connected to the Transceiver and Retroreflector and switched on,before the instrument is mounted on to the flanges.

3 Check that each mounting stud has six pairs of spring washers (1), each pair opposed asillustrated below. On top of the six washers, next to the M12 nut (3), should be ahemispherical washer (2) with the flat side towards the M12 nut.

123

4 Ensure that the rubber sealing bands are replaced loosely around the front sections of theTransceiver and Retroreflector.

Continue on next page.


16

5 Remove the three M12 nuts (4) from the Transceiver mounting flange (1), and locate theTransceiver purge flange (2) on to the studs (3). Replace the Nyloc nuts (4) and tighten them,compressing the spring washers (5), until there is a gap of 13mm (½) between the twoflanges (1 and 2), all round. Pull the sealing band (6) into place over the gap.

123

4 5 6

13 (½")

6 Install the Retroreflector as on 5 above.

CAUTION

Ensure that the air purge system is connected and operating, even if theinstrument is not in use.


17

A4-4 Local Control Unit Installation

The connection interface of the Land Instruments International Model 4500 MkII+ Dust and Opacity Monitoris the Termination Box (T-Box). The T-Box is protected to IP65(NEMA4) and should be mounted on a flatvertical surface, within 2.0 metres (6 feet) of the Transmissomter (to allow the interconnection cable toreach). Mark out the position and secure with four M12 (½) bolts and washers (Customer Supplied).

A blank removable plate is provided on the bottom of the T-Box allowing the customer choice of cableentry type.

The warranty on the instrument may be invalidated if entry fittings are not rated toIP65/NEMA4 and damage occurs due to entry of water or other substances.

The wiring to the T-Box includes power connections to the Transceiver, cables to the optional fault indicators(blower pressure switches, etc.), two analogue outputs, alarm and status relay outputs.

Automatic calibration cycles can be initiated by the T-Box. The customer may prefer to have an externaldevice initiate the calibration cycle (for instance, when used with other Continuous Emissions MonitoringSystem or Continuous Opacity Monitoring Systems). This can be achieved by placing a contact closureacross Din Rail terminals 36 and 37.

300 (11.8)

400 (15.8)

210

(8.

3)

120 (4.7

)

2 slots Ø8.5 (0.3)

CAUTIONDANGER

180

(7.

0)

2 holes Ø8.5 (0.3)

CAUTION

Model 4500 MkII+ Dust and Opacity Monitor Installation and Maintenance Manual

18

A5 Fail Safe Shutter

The Fail Safe Shutter Air Purge Units protect the optical surfaces from corrosive stack gases in theevent of air supply failure. Protective shutters are opened by the air pressure from the Air Blower Unitsto allow normal operation of the instrument. If the air supply fails, the air pressure drops and theshutters close via a counter weight mechanism as illustrated below.

NOTE

Shutters provide temporary protection only. If there is prolonged air failure the Transceiverand Retroreflector should be removed.

1 2

3

(Side View) (Front View)

Fail Safe Shutter Air Purge Unit

Key.

1. Protective Safety Shutter (open position)2. Counter weight (open position)3. Control Blade (open position)

Installation and Maintenance Manual Model 4500 MkII+ Dust and Opacity Monitor

19

A6 Electrical Installation

A6-1 Electrical Connections Overview

All switch cabinets, distribution boxes, fuses and other components for electrical installation must beprovided by the customer, as must the mains power supply connections. Installation should be carriedout by a competent person and cables should satisfy current carrying capacity and voltage rating.

Mains Supply

The following mains power supply connections must be made for:

Termination Box (T-Box)Air Blower Unit/sControl Room Unit (optional)Additional equipment (i.e. chart recorder etc.)

Signal Connections

The following signal cables must be connected via the Termination Box:

Umbilical cable to TranscieverAir Blower pressure switch interconnectionsControl Room Unit (optional)Customer AlarmsCurrent Loop Maintenance Switch

Optional Connections

The following cable connections must be made where required by the application

Status relay connectionsSerial data communications

Air Blower Motor Connections

Refer to the instruction manual for each blower.


20

Electrical Connections Overview

The system is connected as illustrated in the diagram below.

Electrical Connections System Overview

1 Model 4500 MkII+ Transceiver2 Model 4500 MkII+ Retroreflector3 Termination Box4 Air Blower with Filters5 Umbilical cable

6 Instrument Power Input7 Blower Pressure Switch Trip Output8 Blower Power Input9 External power isolator10 External power isolator with fuse

CAUTIONDANGER

1 2

3

5

6

9

7

8

4

10


21

A6-2 System Cables

The following list of cable types (see diagram previous page) is recommended by Land InstrumentsInternational:

Electrical No. of Core Size Core Size Core Size Screened SuppliedConnections Cores mm2 strands/dia awg By

Overview

1 18 0.5 16/0.2 22 YES LAND2 3 1.5 to 4.0 16/0.2 to 56/0.3 16 to 12 NO Customer3 4 0.5 to 1.5 16/0.2 to 30/0.2 22 to 16 NO Customer4 3 1.0 32/0.2 18 NO Customer

CAUTIONDANGER

1

342


22

A6-3 Customer Connection Details to Termination Box

IMPORTANT

Isolate the mains supply before making any connection to the Termination Box. Thisinstrument must be earthed/grounded.

Cable entries are not supplied as standard. The blank plate may be removed and cut out for suitableconduit or other type of entry.

Terminal No. Function Designation

1 Mains Power Live2 Neutral3 Earth

4 Current Loop O/P 1 +ve5 screen6 -ve

7 Current Loop O/P 2 +ve8 screen9 -ve

10 System OK Fault11 Common12 OK

13 Alarm 1 OK14 Common15 Alarm Active

16 Alarm 2 OK17 Common18 Alarm Active

19 Zero Calibration Run20 Common21 In Progress

22 Span Calibration Run23 Common24 In Progress

25 Maintenance Run26 Common27 Maintenance

28 Blower Fail #1 Input29 Return

30 Blower Filter Blocked #1 Input31 Return

32 Blower Fail #2 Input33 Return

34 Blower Filter Blocked #2 Input35 Return

36 Calibration Trigger Input37 Return

38 Modbus Y (Tx)39 RS485 / RS232 Z(/Tx)40 see section A6.5 for details A (Rx)41 B (/Rx)42 Common43 Screen


23

A6-4 MODBUS Connections

The communication protocol offered as an option on the Model 4500 MkII+ is the MODBUS protocol.Based on the RS232/RS485 three wire half duplex hardware standard it provides direct access tosystem data via the T-Box terminal connections 38 - 43.

The MODBUS PCB is manufactured to accept RS 232 or RS 485 connection using the switch selectorfitted inside the termination box. The switch is located inside the T-Box, and is clearly labelled.

IMPORTANT

Where RS 232 is selected as the Modbus communications protocol, the existing 120 Ωtermination resistor requires disconnecting between terminals 40 and 41 inside the T-Box.

The resistor must be retained for RS 485 Modbus communications.

WARNING

Isolate the mains supply before making any electrical adjustments to the T-Box. Thisinstrument must be earthed/grounded.

38 39 40 41 42 43

(Tx)(Rx) Common

RS 232

38 39 40 41 42 43

A (Rx)

B (/Rx)

Y (Tx)

Z (/Tx)

Common

RS 485, 4 Wire, full duplex

38 39 40 41 42 43

A B Common

RS 485, 2 Wire, half duplex

(Tx) (Rx) COM Y (Tx)

Z (/Tx)

A (Rx)

B (/Rx)

COM

REMOTE DEVICE

(Tx) (/Tx) (Rx) (/Rx) COM

REMOTE DEVICE REMOTE DEVICE

24


B1 General Description

The Land Instruments International Model 4500 MkII+ Continuous Opacity Monitoring System (COMS)measures opacity by shining a light beam through flue gases. An internal microprocessor calculatesdust density and other parameters. The instrument comprises the following parts: The Transceiverwhich contains all of the electronic and electrooptic components; the Retro-Reflector containing acorner cube reflector; the Termination Box where the customer terminations are located; and the airpurge system. An optional data display Control Room Unit is available.



TerminationBox

Transceiver

Retro-Reflector

25


Analogue Output

The Model 4500 MkII+ Dust and Opacity Monitor has two current loop outputs available. Each one maybe set independent of the other to output one of the six functions below:

Opacity DustConstant Current Calibration DriftOptical Path Length Ratio Optical Density

All the options can be set to TRACK or HOLD the measurement signal during calibration routines.If TRACK is set, the measurement signal will continue to be output during calibration and if HOLDis set the measurement signal will remain at the last recorded reading before calibration until thecalibration routine is complete.

Relay Outputs

Located on the key panel of the 4500 MkII+ are five LEDs which light to indicate the operation of thefollowing relay outputs:

System OKZero Calibration In ProgressSpan Calibration in Progress2 Alarms

Remote Calibration Initiation

Calibration of the monitor may be initiated remotely from the optional Control Room Unit (panel or wallmounted) or via Modbus control.

Computer Interface Operation

The Model 4500 MkII+ Dust and Opacity Monitor may be connected to a computer or data acquisitionsystem via an RS232 or RS485 Modbus interface inside the Termination Box.


26

B2 Getting Started

B2-1 The Control Panel

The Model 4500 MkII+ is operated from the User Interface in the Transceiver. The User interface isoperated via various function keys. It has five illuminated indicators, a contrast control and a maintenancekey.

The liquid crystal display normally indicates the opacity measured by the instrument. Error messagesand other parameters can also be displayed, as explained in a later section. The displayed opacity iscorrected for Optical Path Length Ratio (OPLR) sometimes referred to as Pathlength Correction Factor(PLCF) (OPLR = 0.5 x PLCF) The OPLR is factory set and cannot be changed by the customer (seesection C1-3).

7

8

10

1 2 3 4 5

6

9

User Interface

Key

1. System status 6. Contrast control2. Alarm 1 status 7. LCD3. Alarm 2 status 8. Maintenance key4. Zero Calibration in progress 9. Menu exit key5. Span Calibration in progress 10. Function keys


27

B2-2 Function Keys

The following function keys are located on the user interface.

Key Function

ENTER Generally used for selecting menu items and for making andsaving changes.

or Scrolls the main and secondary menus

or Scrolls sub menus and selects/alters parameters for changes

EXIT Returns to the previous menu level.

Maintenance Key - the instrument must be unlocked before anyparameter setup or adjustment can take place.

Contrast Control

Maintenance Key Operation

The instrument is unlocked by holding the key down for a period of 3 seconds. Once unlockedthe red LED will illuminate. The instrument will then request a password. The default password is 10.To return the instrument to normal operation, the key must be pressed for 1 second. The red LED willthen go off.

NOTE

No Modbus communication is possible whilst the instrument is unlocked.

Contrast Key Operation

The Contrast control should be used to vary the LCD display contrast.

Press + to increase contrastPress - to decrease contrast


28

B2-3 Glossary of Terms

Op ...............................OpacityO.D. ............................Optical DensityDust ............................Dust DensityAveraging 1 .................Time period used to calculate block average of output 1Averaging 2 .................Time period used to calculate block average of output 2Status ..........................System Status FaultsLoop O/P 1 ..................Current loop output 1 reading in mALoop O/P 2 ..................Current loop output 2 reading in mALast Zero .....................Last zero calibration valueLast Span .................... Last span calibration valueCal. Drift ......................Drift of signal between calibrations (range 0.1 to 1.0)Version ........................Software Version NumberBlank ...........................A blank lineSo ...............................Signal Detector OffsetSf ................................Signal Detector Flood ValueSm ..............................Signal Detector MeasurementRo ...............................Reference Detector offsetRf ................................Reference Detector Flood ValueRm ..............................Reference Detector MeasurementC .................................Calibration ConstantX .................................Calibration constantB .................................Balance correctionG .................................Gain correction factorQ .................................Uncorrected transmission factorDust Gain ....................Constant relating Optical Density to Dust Density.Dust Offset ..................Optical Density v Dust Density zero offset (usually zero)Zero Damper ...............Low pass digital filter applied to zero readingFlood Damper ............. Low pass digital filter applied to flood LEDCal Damper .................Low pass digital filter applied to calibrationOP 1 Damper ..............Low pass digital filter applied to output 1OP 2 Damper ..............Low pass digital filter applied to output 2PLCF...........................Path Length Correction FactorOPLR ..........................Optical Path Length RatioLast Cal. ......................Data stored from the latest calibrationZero Comp. .................Opacity compensation due to dust build on the lensIsokinetic O.D. ............Average Optical Density calculated during gravimetric testRunning In ..................Positioning the zero reflector or upscale filter to an active positionRunning Out ................Positioning the zero reflector or upscale filter to an inactive position


29

↑↓

↵↵↵↵↵

↑↓

EXIT

Opacity: 0.0%Parameters: ↔↵↵↵↵↵

OPLR: 0.5↑↓

So: 0↑↓

Opacity: 0.0%Parameters: ↔↵↵↵↵↵

Opacity: 0.0%Faults: ↑↓↵↵↵↵↵

B2-4 Using the Instrument for the First Time

The following instructions must be adhered to for the correct running of the instrument.

1. Complete Installation

Ensure installation has been completed, including any optional equipment e.g. Control Room Unit (CRU).

2. Check Display is Legible

Once the instrument is powered up, check that the LCD display has acceptable visibility. Adjust thedisplay contrast using the key as appropriate.

3. Check the Optical Pathlength Ratio. See section C1-3.

.

Check the OPLR is correct and then continue to align the instrument.

1. Press and hold the maintenance key for a period of 3seconds, until the red LED illuminates.

2. Enter the password using the ↑ and ↓ keys, then press Enter.The default password is 10.

3. Scroll through the menu spine using the ↑ and ↓ keys untilPARAMETERS is displayed then press the ENTER (↵) key.

4. Scroll through the PARAMETERS menu using the ↑ and ↓keys until OPLR is displayed.

5. If the OPLR is correct press the EXIT key to return to themenu spine. If it is incorrect, the instrument must be returnedto Land Instruments International for reprogramming.

Now set the instrument to alignment mode.


30

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

↵↵↵↵↵

4. Set the Instrument to Align Mode


Opacity: 0.0%Setup: ↑↓↵↵↵↵↵

Align ModeSignal: 235.3↵↵↵↵↵

Opacity: 0.0%Align: ↑↓↵↵↵↵↵

Opacity: 0.0%Miscellaneous: ↑↓↵↵↵↵↵

Opacity: 0.0%Outputs: ↑↓↵↵↵↵↵

Accurate alignment is essential if the Model 4500 MkII+ is to function correctlyand meet its design specification.

1. Scroll through the menu spine using the ↑ and ↓ keys untilSETUP is displayed then press the ENTER (↵↵↵↵↵) key.

2. Scroll through the SETUP menu using the ↑ and ↓ keys untilMiscellaneous is displayed and then press the ENTER (↵↵↵↵↵) key.

3. The word Align should now be displayed (if not use the ↑ and ↓keys to scroll through the Miscellaneous menu until Align isdisplayed). Press the ENTER (↵↵↵↵↵) key and a Signal value isdisplayed, the instrument is now in Align mode.

In Align mode, the normalisation function is disabled so that themeasurement LED appears to be lit constantly, thereby assisting visualalignment using the alignment targets on the Transceiver and Retro-Reflector. In addition the word 'Signal' followed by a numberproportional to the measured intensity is displayed on the LCD display.

Now align the Retro-Reflector.


31

5 Align the Retro-Reflector

Opening the Retro-Reflector Case and Releasing the Reflector

1. Open the Retro-Reflector case by undoing the two quick-release clamps.2. Release the Retro-Reflector Mount by unscrewing the two captive socket head screws on

either side of the Retro-Reflector Mount and allow the Retro-Reflector to drop into a horizontalposition.

3. Close the case and fasten the quick-release clamps.

Retro-Reflector Alignment TargetWARNING

Eye and face protection must be worn when looking into hot gases.

4. Observe the alignment target through the window (3). A bright green spot (4) should be visible.

CaptiveSocketHead

Screws

QuickRelease

Clip

1

3

2

4


32

5. If the green spot is not visible undo the quick release clamps on the Retro-Reflector andlook down the purge barrel. The bright green light from the Transceiver should be clearlyvisible. If not, then the Transceiver is either grossly misaligned or the instrument ismalfunctioning.

6. To move the green spot horizontally adjust the M12 nut (1) on the air purge flange and tomove it vertically, adjust the M12 nuts (2), also on the air purge flange as illustrated above.Adjust these nuts until the green spot is central in the inner circle.

7. In bright sunshine the green spot on the alignment target may not be visible. In this casereturn to the Transceiver, undo the quickrelease clamps and swing the instrument awayfrom the purge. It should now be possible to adjust the Retro-Reflector until the bright circleof sunlight, visible through the Transceiver purge unit, is centred on the target.

8. Ensure that the 6 pairs of spring washers between the air purge flange and the mountingflange are under moderate tension. It is important that the instrument is firmly held in placeto maintain optical alignment.

9. Open the Retro-Reflector case and re-fix the Retro-Reflector in position by tightening thecaptive socket head screws. Close the Retro-Reflector case and fasten the two quick-releaseclamps.

10. Now align the Transceiver.


33

6 Align the Transceiver

Transceiver Alignment Target

1. Observe the alignment target through the window (3). A bright green spot (4) should be visible.

2. To move the green spot horizontally adjust M12 nut (1) on the air purge flange and to move itvertically, adjust the M12 nuts (2), also on the air purge flange as illustrated above. Adjustthese nuts until the green spot is inside the inner circle.

3. In bright sunshine the green spot on the alignment target may not be visible. In this casereturn to the Retro-Reflector, undo the quickrelease clamps and swing open the rear cover.It should now be possible to adjust the Transceiver until the bright circle of sunlight, visiblethrough the Retro-Reflector purge unit is centred on the target. Close the Retro-Reflectoragain. If the green spot is visible, adjust the nuts until it is central within the inner circle. Ifthis is not possible, then adjust for maximum signal level.

4. Ensure that the 6 pairs of spring washers between the air purge flange and the mountingflange are under moderate compression. If the compression becomes excessive, it is likelythat the third nut has been over tightened or the mounting flange may not have been fittedaccurately.

5. On the User interface press the Maintenance key and hold for 1 second to exit. The red LEDwill be extinguished.

Once the instrument has been correctly aligned configure the calibration options.

3

2

1

4


34

↵↵↵↵↵

EXIT

↵↵↵↵↵

↵↵↵↵↵

↑↓

↑↓

↵↵↵↵↵

7. Setup Calibration Check Intervals


Opacity: 0.0%Calibration: ↑↓↵↵↵↵↵

Opacity: 0.0%Cal check: ↑↓↵↵↵↵↵

Opacity: 0.0%Cal Setup: ↑↓↵↵↵↵↵

Opacity: 0.0%Interval: 24h↑↓↵↵↵↵↵

Opacity: 0.0%Interval: 10↵↵↵↵↵


The Model 4500 MkII+ Dust and Opacity Monitor may be programmed toperform a calibration check at preset intervals. Alternatively the timer canbe disabled (set time interval to zero) and the instrument will calibrateonly in response to an external trigger (momentary contact closure acrossterminals 36 and 37 inside the Termination Box).

1. Press and hold the maintenance key for a period of 3 seconds,until the red LED illuminates.

2. Enter the password using the ↑ and ↓ keys, then press Enter.The default password is 10.

3. Scroll through the menu spine using the ↑ and ↓ keys untilCALIBRATION is displayed then press the ENTER (↵↵↵↵↵) key.

4. Scroll through the CALIBRATION menu using the ↑ and ↓ keysuntil Cal Setup is displayed and then press the ENTER (↵↵↵↵↵) key.

5. The word Interval is displayed (if not use the ↑ and ↓ keys toscroll through the menu until Interval is displayed). Press theENTER (↵↵↵↵↵) key (notice the underlined character). Now selectthe interval between automatic calibration checks by pressingthe ↑ and ↓ keys. Once selected press the ENTER (↵↵↵↵↵) key toset the value and the EXIT key to return to the Cal Setupdisplay.

Continue with calibration setup.


35

↑↓

EXIT

↵↵↵↵↵

↑↓

↵↵↵↵↵

↵↵↵↵↵

↑↓

6. Press the ENTER (↵↵↵↵↵) key from the Cal Setup display to returnto the Cal Setup menu. Scroll through the Cal Setup menuusing the ↑ and ↓ keys until Time To Next Cal is displayed andthen press the ENTER (↵↵↵↵↵) key (notice the underlinedcharacter).

7. Press the ↑ and ↓ keys to select the number of hours to waitbefore performing the first automatic calibration check, and thenpress the ENTER (↵↵↵↵↵) key (notice the underlined character haschanged). Now press the ↑ and ↓ keys again, this time to selectthe number of minutes (added to the hours) to wait beforeperforming the first automatic calibration check. Press theEXIT key to set and return to the Cal Setup display.

8. Press the EXIT key again to return to the menu spine and turnthe Maintenance key to RUN (No LED).

Now setup the current loop outputs.


Time To Next Cal0 h 0 mins↑↓↵↵↵↵↵



EXIT


Opacity: 0.0%Calibration: ↑↓↵↵↵↵↵


36

↑↓

↵↵↵↵↵

↵↵↵↵↵

8. Setup Current Loop Outputs

↵↵↵↵↵

↵↵↵↵↵




Opacity: 0.0%Output 1: ↑↓↵↵↵↵↵

Outputs 1: ↑↓↵↵↵↵↵Opacity

Outputs 1: ↔↵↵↵↵↵Opacity

The Model 4500 MkII+ Dust and Opacity Monitor has two independentcustomer outputs available. Each signal output interval may be altered bysetting the Average 1 and Average 2 displays accordingly.



3. The word Outputs is now displayed (if not use the ↑ and ↓ keysto scroll through the menu until Outputs is displayed). Nowpress the ENTER (↵↵↵↵↵) key.

4. The word Output 1 is now displayed (if not use the ↑ and ↓ keys toscroll through the menu until Output 1 is displayed). Press theENTER (↵↵↵↵↵) key and the Opacity option is displayed (this mayvary if previously altered), press the ENTER key again (notice theunderlined character).

Continue with output setup.


37

5. Use the ← and → keys to select the required option for Output 1and then press the ENTER (↵↵↵↵↵) key (notice no underlinedcharacter). Press the ↑ and ↓ keys to scroll to the Rangeoption and press the ENTER (↵↵↵↵↵) key again to display theunderlined character (The Constant Current option is used fordiagnostic purposes and is detailed in section B3-5).

6. Press the ↑ and ↓ keys to select the maximum reading to beallocated to the maximum output and then press the ENTER(↵↵↵↵↵) key (notice no underlined character). Now press the ↑ and↓ keys again to select the During Cal option and press theENTER (↵↵↵↵↵) key.

7. Using the ← and → keys select TRACK (to continue the outputsignal during automatic calibration checks) or HOLD (to retainthe last reading before the automatic calibration check until thecalibration is completed). Press the ENTER (↵↵↵↵↵) key to set theoption (notice no underlined character) and then the press EXITkey to return the display to Output 1.

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

EXIT


Outputs 1: ↑↓↵↵↵↵↵OD

Outputs 1: ↑↓↵↵↵↵↵Range: 1.6


Outputs 1: ↑↓↵↵↵↵↵During Cal: TRACK

Outputs 1: ↑↓↵↵↵↵↵During Cal: HOLD



38

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↵↵↵↵↵

↵↵↵↵↵

8. To set the second customer output, use the ↑ and ↓ keys toselect Output 2 and then press the ENTER (↵↵↵↵↵) key. Repeatsteps 4 to 6 previous.

9. From the Output 1 or Output 2 display press the ↑ and ↓ keysto select the Averaging 1 display and then press the ENTER(↵↵↵↵↵) key. Press the ENTER (↵↵↵↵↵) key again (notice the underlinedcharacter).

10. If the Averaging 1 option is set to OFF the Output 1 signal iscontinuously output. If the Averaging 1 is set to ON theOutput 1 signal is averaged over the selected period. Pressthe ← and → keys to select ON to average the output (Set toOFF if not required) and press the ENTER (↵↵↵↵↵) key.

11. Set the hours (h) by pressing the ← and → keys and then theENTER (↵↵↵↵↵) key. Set the minutes (m) and seconds (s) in asimilar way.


→←


Averaging 1: OFF0h 0m 0s


Averaging 1: ON0h 0m 0s

↵↵↵↵↵

→←

↵↵↵↵↵

→←






39

EXIT

EXIT

12. Once the required averaging time period has been selected andset, press the EXIT key to return to the Averaging 1 display.

13. To set the averaging option for the second customer output, usethe ↑ and ↓ keys to select Averaging 2 and then press theENTER (↵↵↵↵↵) key twice (notice the underlined character).Repeat steps 10 to 12 previous.

14. Press the EXIT key twice to return to the menu spine.

Now setup the alarms.

EXIT

↵↵↵↵↵

↵↵↵↵↵

↑↓


Opacity: 0.0%Averaging 1: ↑↓↵↵↵↵↵






40

9. Setup Alarms

↑↓

↑↓

↵↵↵↵↵

↵↵↵↵↵




Opacity: 0.0%Alarms: ↑↓↵↵↵↵↵

Opacity: 0.0%Alarm 1: ↑↓↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

Opacity: 0.0%AL1 type: Opacity


The Model 4500 MkII+ has two customer alarms available. Each alarm maybe set to trip at a specified level for Optical Density, Opacity or Dust. A delayof between 0 to 30 seconds is also available for each alarm.


2. Scroll through the SETUP menu using the ↑ and ↓ keys untilAlarms is displayed and then press the ENTER (↵↵↵↵↵) key.

3. The word Alarm 1 should now be displayed. Press the ↑ and ↓keys to select between the two available alarms, Alarm 1 andAlarm 2 and then press the ENTER (↵↵↵↵↵) key. The alarm type(AL1 type) is now displayed as Opacity (this may vary ifpreviously adjusted). Press the ENTER key again (notice theunderlined character).


41

4. Use the ← and → keys to select the required measurement(Optical Density, Opacity or Dust) to be alarmed and then pressthe ENTER (↵↵↵↵↵) key (notice no underlined character). Press the↑ and ↓ keys to scroll to the AL1 trip (or AL2 trip if settingAlarm 2) option and press the ENTER (↵↵↵↵↵) key again (noticethe underlined character).

5. Press the ↑ and ↓ keys to select the required level at which thealarm is to trip and then press the ENTER (↵↵↵↵↵) key (notice nounderlined character). Now press the ↑ and ↓ keys again toselect the Delay option and press the ENTER (↵↵↵↵↵) key (noticethe underlined character).

6. Using the ↑ and ↓ keys select the required time period for theAlarm to be delayed and press the ENTER (↵↵↵↵↵) key (notice nounderlined character). Press the EXIT key twice to return to themenu spine.

Now perform a Calibration Check

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

EXIT


Opacity: 0.0%AL1 type: O.D.

Opacity: 0.0%AL1 trip: 0.00


Opacity: 0.0%Delay: 5s




42

10 Perform Calibration Check

The instrument will be ready for use on completion of Cal check. The simplest way to perform this isas follows:

1. Power down the instrument.2. Power up the instrument and a calibration check will be performed automatically.3. Allow three minutes for the calibration check to be completed and then check that the

System OK LED is on.4. The Model 4500 MkII+ is now in operation.

NOTE

The current loop outputs will initially read zero until the first averaging period is complete.

If the MODBUS option is used continue with setup, otherwise, the instrument is ready for operation.


43

11 MODBUS Option

MODBUS is a communications system based on the RS232/RS485 hardware standard and providesdirect access to the Model 4500 MkII+ system data via the Termination Box. It is a standard feature onthis model. Details are available from the Modbus website: www.modbus.org.

The instrument is factory set to RS232. Where RS485 is required, the switch (fitted inside theTermination Box) must be moved to the lower position. The switch is situated on the underside of theboard adjacent to the label (as illustrated). It has two positions.

RS232 - UpRS485 - Down

Three LEDs situated on the underside of the main board (inside the T-Box) will flash when is is fullyfunctional. This provides a visual indication that the Modbus system is working. The light from theLEDs is clearly visible, reflected by the right hand side of the case.

232

485

Troubleshooting

If problems arise when setting up the Modbus communications then go through the following checklist.

1. Check the Station number is 1 and the Link Not Fitted are correct in the instrument settings.2. If you are using RS232 and one LED is permanently ON, then check the selector switch is in theUp position.3. If you are using RS485 and no LEDs are ON, then check the selector switch is in the Downposition.

IMPORTANT

Modbus communications are not possible when the instrument is in maintenance mode.


44

↑↓

Setup Menu MODBUS Options

Set Station Number and Link options on the Miscellaneous menu under Setup on themenu spine (see section C4-4 Setup Screens).

The Model 4500 MkII+ has two options that require setting for correct useof the MODBUS communications protocol.



3. Scroll through the SETUP menu using the ↑ and ↓ keys untilMiscellaneous is displayed and then press the ENTER (↵↵↵↵↵)key.

4. Scroll through the Miscellaneous menu using the ↑ and ↓ keysuntil Station number is displayed and then press the ENTER(↵↵↵↵↵) key (notice the underlined character).

NOTE: Station Number should be set to 1.

↑↓

↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵




Opacity: 0.0%Miscellaneous: ↑↓↵↵↵↵↵

Opacity: 0.0%Align: ↑↓↵↵↵↵↵

Opacity: 0.0%Station number: x



45

EXIT

EXIT

5. The Station Number indicates the location of the instrument tothe user control system via the MODBUS communicationprotocol. Press the ↑ or ↓ key to select the required value thenpress the ENTER' (↵↵↵↵↵) key to set the option (notice nounderlined character).

6. Scroll through the Miscellaneous sub-menu again by pressingthe ↑ ↓ keys until the Link option is displayed and then pressthe ENTER (↵↵↵↵↵) key (notice the underlined character).

NOTE: Should be set to Link not fitted.

7. Press the ↑ or ↓ key to select the required value then press theENTER' (↵↵↵↵↵) key to set the option (notice no underlinedcharacter). It is now possible to scroll through theMiscellaneous sub-menu by pressing the ↑ ↓ keys.

8. Press the EXIT key to return to the SETUP menu and thenagain to return to the Menu Spine.

Instrument is now ready for operation.

↵↵↵↵↵

↑↓

↑↓

↵↵↵↵↵

↵↵↵↵↵

↑↓



Opacity: 0.0%Link: Not fitted




Model 4500 MkII+ Dust and Opacity MonitorInstallation and Maintenance Manual

46


2. Scroll through the menu spine using the ↑ and ↓ keys untilSETUP is displayed then press the ENTER (↵) key.

3. Scroll through the SETUP menu using the ↑ and ↓ keys untilAlarms is displayed and then press the ENTER (↵) key.

4. The word Alarm 1 should now be displayed. Press the ↑ and ↓keys to select between the two available alarms, Alarm 1 andAlarm 2 and then press the ENTER (↵) key. The alarm type(AL1 type) is now displayed as Opacity (this may vary ifpreviously adjusted). Press the ENTER key again (notice theunderlined character).

Continue to step 5.

B3 Normal Modes of Operation

B3-1 Alarm Setup

The Model 4500 MkII+ has two customer alarms available. Each alarm may be set to trip at a specifiedlevel for Optical Density, Opacity or Dust. A delay of between 0 to 30 seconds is also available for eachalarm.

↑↓

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓




Opacity: 0.0%Alarms: ↑↓↵↵↵↵↵





47

5. Use the ← and → keys to select the required measurement(Optical Density, Opacity or Dust) to be alarmed and then pressthe ENTER (↵) key (notice no underlined character). Press the↑ and ↓ keys to scroll to the AL1 trip (or AL2 trip if settingAlarm 2) option and press the ENTER (↵) key again (noticethe underlined character).

6. Press the ↑ and ↓ keys to select the required level at which thealarm is to trip and then press the ENTER (↵) key (notice nounderlined character). Now press the ↑ and ↓ keys again toselect the Delay option and press the ENTER (↵) key (noticethe underlined character).

7. Using the ↑ and ↓ keys select the required time period for the Alarm tobe delayed and press the ENTER (↵) key (notice no underlinedcharacter). Press the EXIT key to return the display to Alarm 1.

8. Press and hold the Maintenance key fro 1 second to return to RUNmode (no LED illuminated).

The instrument alarms are now set.

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

EXIT


Opacity: 0.0%AL1 type: O.D.







48

↑↓

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

B3-2 Output Setup







The Model 4500 MkII+ Dust and Opacity Monitor has two independentcustomer outputs available. Each signal output interval may be altered bysetting the Average 1 and Average 2 displays accordingly.


2. Scroll through the menu spine using the ↑ and ↓ keys untilSETUP is displayed then press the ENTER (↵) key.

3. The word Outputs is now displayed (if not use the ↑ and ↓ keysto scroll through the menu until Outputs is displayed). Nowpress the ENTER (↵) key.

4. The word Output 1 is now displayed (if not use the ↑ and ↓ keys toscroll through the menu until Output 1 is displayed). Press theENTER (↵) key and the Opacity option is displayed (this mayvary if previously altered), press the ENTER key again (notice theunderlined character).

Continue to step 5.


49

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

EXIT

5. Use the ← and → keys to select the required option for Output 1and then press the ENTER (↵) key (notice no underlinedcharacter). Press the ↑ and ↓ keys to scroll to the Range optionand press the ENTER (↵) key again to display the underlinedcharacter (The Constant Current option is used for diagnosticpurposes and is detailed in section B3-5).

6. Press the ↑ and ↓ keys to select the maximum reading to beallocated to the maximum output and then press the ENTER(↵) key (notice no underlined character). Now press the ↑ and↓ keys again to select the During Cal option and press theENTER (↵) key.

7. Using the ← and → keys select TRACK (to continue the outputsignal during automatic calibration checks) or HOLD (to retainthe last reading before the automatic calibration check until thecalibration is completed). Press the ENTER (↵) key to set theoption (notice no underlined character) and then the press EXITkey to return the display to Output 1.

Continue to step 8.


Outputs 1: ↑↓↵↵↵↵↵During Cal: TRACK

Outputs 1: ↑↓↵↵↵↵↵During Cal: HOLD


↵↵↵↵↵

→←

↵↵↵↵↵

↑↓


Outputs 1: ↑↓↵↵↵↵↵OD



50

↵↵↵↵↵

↑↓

↵↵↵↵↵

↵↵↵↵↵

→←

8. To set the second customer output, use the ↑ and ↓ keys toselect Output 2 and then press the ENTER (↵) key. Repeatsteps 5 to 7 above.

9. From the Output 1 or Output 2 display press the ↑ and ↓ keysto select the Averaging 1 display and then press the ENTER(↵) key. Press the ENTER (↵) key again (notice the underlinedcharacter).

10. If the Averaging 1 option is set to OFF the Output 1 signal iscontinuously output. If the Averaging 1 is set to ON theOutput 1 signal is averaged over the selected period. Pressthe ← and → keys to select ON to average the output (Set toOFF if not required) and press the ENTER (↵) key.

Continue to step 11.




↵↵↵↵↵

↑↓

↵↵↵↵↵



Opacity: 0.0%Outputs 1: ↑↓↵↵↵↵↵



51

11. Set the hours (h) by pressing the ← and → keys and then theENTER (↵) key. Set the minutes (m) and seconds (s) in asimilar way.

Continue to step 12

↵↵↵↵↵

→←

↵↵↵↵↵

→←

↵↵↵↵↵

→←






52

12. Once the required averaging time period has been selected andset, press the EXIT key to return to the Averaging 1 display.

13. To set the averaging option for the second customer output, usethe ↑ and ↓ keys to select Averaging 2 and then press theENTER (↵) key twice (notice the underlined character).Repeat steps 9 to 11 above.

14. Press the EXIT key twice to return to the menu spine andthen press the maintenance key for 1 second to switch intoRUN mode (no LED illuminated).

The instrument outputs are now set.EXIT

EXIT

↵↵↵↵↵

EXIT

↵↵↵↵↵

↑↓







53

B3-3 MODBUS Communications

MODBUS is a communications system based on the RS232/RS485 three wire half duplex hardwarestandard and provides direct access to the Model 4500 MkII+ system data via the instrument serialport. MODBUS can be used to:

a) read any of the parameters measured by the Instrumentb) check the instrument statusc) initiate a check cycle calibration

NOTE

Changing the calibration constants may fundamentally affect the operation of the instrument.

The instrument functions as a MODBUS slave device in accordance with the MODBUS protocol (asdefined by Modicon)

Details of the MODBUS standard are available from www.modbus.org.

Before communicating with Model 4500 MkII+ via the MODBUS interface, it is necessary to set theStation No. (the MODBUS slave address) and the Link options to an appropriate value. The twooptions are located in the Miscellaneous menu under Setup on the menu spine (see Setup Screenssection C4-4).

The system data for the Model 4500 MkII+ is accessible via register numbers as shown on the SystemData Register Table shown in this section.

NOTE

There is a possible source of confusion in the definition of Register Numbers used inMODBUS functions. For historical reasons, user reference numbers are expressed asdecimal numbers with a starting offset of 1; so a Modbus message requesting a read atAddress Offset 0 would return the value in Register 1. The System Data Register Tablegiven uses Register Numbers rather than address offsets.


54

Commands

Mobus communications will be limited to the following command subset:

Command MODBUS Function Notes

03 Read Holding Register Read Register (single or block)06 Pre-set Register Write to Single Register

10 (Hex) Pre-set Multiple Registers Write to Multiple Registers

NOTE

(03) The block read command is limited to a maximum of 10 registers(06) Only one register at a time may be changed with this command(10 Hex) Required in order to change floating point or 32 bit variables, which span two registers

Registers

A MODBUS register holds a 16 bit data value. The following table indicates the range of data typesthat the system parameters encompass, with a description of how they are accessed as registers.

Variable Type Description

Character 8 bit. As the minimum data size is 16 bit, character variables (suchas system status) will reside in the lower 8 bits of the returnedregister value.

Integer 16 bit. Single register.Long 32 bit. These will be placed in two consecutive registers, MSB first.

Floating Point 32-bit variables located in two consecutive registers. IEEEStandard Floating Point Notation.


55

System Data Register Table

NOTE

Certain registers are read-only. Any attempt to write to these registers will result in thereturn of an error code.

Register # Parameter Data Description Range WriteType Access

25 OPLR Float Optical Path Length Ratio 0.1 - 1.0 NO26 (Previously PLCF)49 Opacity Float Calculated opacity 0.00 - 1.00 NO5051 Optical Density Float Calculated optical 0.00 - 3.00 NO52 density53 Dust Density Float Calculated dust 0.0 - 10 000 NO54 density55 Average Optical Float Average optical density 0.0 - 3.00 NO56 Density during gravimetric test65 Cal Check OPz Float Cal check zero opacity 0.00 - 0.20 NO66 value67 Cal Check OP0 Float Cal check opacity value 0.00 - 0.20 NO6869 Cal Check Float Cal check span opacity 0.00 - 1.00 NO70 Upscale value85 Cal Timer 16-bit Calibration timer counter NO

(seconds)86 Motor Timer 16-bit Motor timer counter (5mS) NO87 Error Flags 32-bit Error flags* NO88104 System State 8-bit System status* YES105 System Mode 8-bit System operating mode* NO106 Cal Status 8-bit Calibration status* NO

For registers marked * see over page


56

Register # Parameter Data Description Range WriteType Access

110 OP1 Span Float CLOP 1 range 0.0 - 3.0 YES111 Optical Density optical density112 OP1 Span Float CLOP 1 range 0.0 - 1.0 YES113 Opacity opacity114 OP1 Span 16-bit CLOP 1 range 0 - 4000 YES

Dust dust density115 OP1 Average Float CLOP 1 average value Dependent on YES116 units of output

(see registers49 to 53)

122 OP1 Bits 16-bit CLOP 1 output bits scaled NO4095 = 20mA

126 OP1 Output 8-bit CLOP 1 output units* YES133 OP2 Span Float CLOP 2 range 0.0 - 3.0 YES

Optical Density optical density134 YES135 OP2 Span Float CLOP 2 range 0.0 - 1.0 YES

Opacity opacity136 YES137 OP2 Span Dust 16-bit CLOP 2 range 0 - 4000 YES

dust density138 OP2 Average Float CLOP 2 average value Dependent on YES139 units of output

(see registers49 to 53)

145 OP1 Bits 16-bit CLOP 2 outputs bits scaled NO4095 = 20mA

149 OP2 Output 8-bit CLOP 2 output units* YES166 Start Calibration 16-bit Start Calibration Normally 0 YES

1 - Initiate Cal.167 Output Relays 16-bit Output relays* - NO168 Calibration Phases 16-bit Calibration Phases - NO

For registers marked * see over pageNOTE

If the calibration is correctly initiated, the Start Calibration register will automatically resetto 0. If the instrument is unable to initiate the calibration (the instrument is in maintenancemode or already in calibration) the register will remain at 1 and the calibration will remainpending. Setting the Start Calibration register to 0 will remove any pending operation.


57

*Further Information On Registers

Error Flags (Register 87 and 88)

CHECKSUM ERROR 0x0000001 Eeprom checksum failureNOT USED 0x0000002 NOT USEDOP0 FAULT 0x0000004 -1 ≤ Op0 ≤ 2OPC FAULT 0x0000008 -1 ≤ OpC ≤ 2OP0 LIMITED 0x0000010 -0.05 -1 ≤ Op0 ≤ Op_0_Limit (default: 0.04)FAIL IN CAL 0x0000020 Motor jammed or manual abortMOTOR JAMMED 0x0010000 Either motor failed to parkMEASURE LED FAIL 0x0020000 (Rm-R0) < 200FLOOD LED FAIL 0x0040000 (Rf-R0) < 200ADC OVERRANGE 0x0080000 Any MAX ADC signal > 279040ADC FAULT 0x0100000 10-bit ADC failed to convertNOT USED 0x0200000 NOT USEDFILTER BLOCKED 0x0400000 External signalBLOWER FAILED 0x0800000 External signalNEGATIVE OPACITY 0x1000000 Opacity < -0.05

System Status (Register 104)

0 NORMAL1 IN CAL CHECK2 IN FACTORY CAL3 MAINTENANCE4 IN ALIGNMENT5 IN MANUAL CAL

System Operating Mode (Register 105)

0 NORMAL3 MAINTENANCE


58

Calibration Status (Register 106)

0 PENDING1 ZERO CHECK2 ZERO TIMING3 UPSCALE CHECK4 UPSCALE TIMING5 MOTOR CHECK6 FINALISE7 ABORTING CAL8 START CAL CHECK9 CALC CONSTANTS10 NOT USED11 SET BALANCE12 EXTERNAL STANDARD13 IN FACTORY CAL14 IN CAL AUDIT15 IN RECAL16 WAITING

CLOP 1 Output Units (Register 126)

0 OPTICAL DENSITY1 OPACITY2 DUST DENSITY3 CONSTANT OUTPUT4 CAL DRIFT5 PLCF

CLOP 2 Output Units (Register 149)

As above

Output Relays (Register 167)

SYSTEM OK RELAY 0x0001 0 - SYSTEM FAIL 1 - SYSTEM OKSPAN CAL IN PROGRESS 0x0002 0 - DEACTIVATED 1 - ACTIVATEDZERO CAL IN PROGRESS 0x0004 0 - DEACTIVATED 1 - ACTIVATEDALARM1 RELAY 0x0008 0 - DEACTIVATED 1 - ACTIVATEDALARM2 RELAY 0x0010 0 - DEACTIVATED 1 ACTIVATED

NOTE

Other bits for internal use only


59

Calibration Phases (Register 168)

Three bits in this register are defined: all other bits are zero. If one bit is true then the others are false.

Bit 0 Zero PhaseTrue during a Calibration Check sequence.Goes true Cal Action Delay seconds before the zero reflector starts to drive in.Goes false before the upscale filter starts to drive in.

Bit 1 Span PhaseTrue during Calibration Check sequence.Goes true Cal Action Delay seconds before the upscale filter starts to drive in (ie simultaneously withBit 0 going false)Goes false Cal Action Delay seconds before the zero reflector and upscale filter start to drive out.

Bit 2 Audit PhaseTrue throughout any Calibration Audit operation.Goes true Cal Action Delay seconds before the zero reflector starts to drive in.Goes false Cal Action Delay seconds before the zero reflector starts to drive out.

Protocol Format

The Model 4500 MkII+ utilises the MODBUS RTU (Remote Terminal Unit) transmission format.

Serial communications are fixed at 1 start bit, 8 data bits, no parity, 1 stop bit, and the data rate is fixedat 9600 baud.

The following are examples of master query and slave response messages in RTU format, pollingslave address 11 (hex).

(03) Read Register(s)

Query Response

Slave Address 11 Slave Address 11Function 03 Function 03Register Address Hi 00 Byte Count 06Register Address Lo 20 Data 1 Hi xxNo. of Registers Hi 00 Data 1 Lo xxNo. of Registers Lo 03 Data 2 Hi xxCRC Hi xx Data 2 Lo xxCRC Lo xx Data 3 Hi xx

Data 3 Lo xxCRC Hi xxCRC Lo xx


60

(06) Preset Register

Query Response

Slave Address 11 Slave Address 11Function 06 Function 06Register Address Hi 00 Register Address Hi 06Register Address Lo 20 Register Address Lo xxData Hi 00 Data Lo xxData Lo 03 Data Hi xxCRC Hi xx CRC Hi xxCRC Lo xx CRC Lo xx

(10 Hex) Preset Multiple Registers

Query Response

Slave Address 11 Slave Address 11Function 10 Function 10Register Address Hi 00 Register Address Hi 00Register Address Lo 01 Register Address Lo 01No. of Registers Hi 00 No. of Registers Hi 00No. of Registers Lo 02 No. of Registers Lo 02Byte Count 02 CRC Hi xxData Hi xx CRC Lo xxData Lo xxData Hi xxData Lo xxCRC Hi xxCRC Lo xx

CRC Generation

See MODBUS Manual.


61

Error Codes

The Model 4500 MkII+ may return the following MODBUS exception codes.

Code Exception Description

01 ILLEGAL FUNCTION The instrument only responds to codes 03, 06 and10 (Hex). Any other function request will result in thereturn of this error.

02 ILLEGAL DATA ADDRESS Register number out of range.03 ILLEGAL DATA VALUE Write request to a read-only register.


62

B4 Periodic Modes of Operation

B4-1 Calibration Check

1 2 8 9

3 6 7 4

10

5

Transceiver1. LED light source 7. Reference Detector2. Flood LED 8. Concave Mirror3. 50/50 Beam Splitter 9. Span Filter4. Collimating Lens 10. Zero Point Reflector5. Collimated Beam 11. Diffuser6. Measurement Detector

The transmissometer periodically performs a two step calibration check. In the first step, a zero-pointreflector (10), mounted within the air purge of the Transceiver is placed into the optical axis. In the secondstep, the span filter (9) is also placed in the light path. The monitor reads the difference in light between thecurrent zeropoint and the zeropoint established during the last clear stack calibration, and notes thisvalue as the amount of drift and optical dust build-up. The opacity value of the span filter (9) is shown on thecalibration certificate which accompanies the instrument.

CAUTION

Do not attempt to move the zero point reflector by hand. The precision gearbox willbe irreparably damaged. See section B4-1 for identification.

11


63

B4-2 Calibration Audit

A convenient Calibration Audit facility is provided, for carrying out the Calibration Audit tests required byUSEPA and other Environmental Regulatory Authorities.

Calibration Audit and Modbus Communications

When the instrument is in maintenance mode Modbus communications are disabled. It is therefore notpossible in this mode to monitor the results of the Calibration Audit and Response Time tests using theModbus.

If Modbus communications are required during a Calibration Audit, follow the instructions in CalibrationAudit Method 2.

Calibration Audit Method 1 (Modbus disabled)

1 Press and hold the Maintenance key unit the red LED illuminates (about 5 seconds).

2 Enter the password using the UP and DOWN arrow keys and then press Enter. The default passwordis 10.

3 Use the DOWN ARROW key to select Calibration and press ENTER.

4 Use the DOWN ARROW key to select CAL AUDIT and press ENTER.

5 The zero reflector is driven into its working position. The displayed value should be 0.00 ± 0.010.Note that this is fractional Opacity, i.e. 100 % is shown as 1.00.

6 Open the transceiver housing by releasing two quick-release clamps, and swing the instrumentopen on its hinges.

6 Insert a calibrated neutral density filter into slot 1.

7 Read and record the displayed opacity value. The instrument should read a value within ±1.0 % ofthe calibration filter. Note that this value will be corrected for the Optical Path length Ratio

1 Filter Slot2 Zero Point Reflector

CAUTIONDo not attempt to move the zero point reflector (2).The precision gearbox will be irreparably damaged.

1

2


64

(OPLR). If the OPLR is set to the default value of 0.5, then the displayed value should match thefilter opacity. If the OPLR is not 0.5, then calculate the corrected value using the formula givenbelow.

7 Remove the filter; insert, read and record the values for the other filters in turn as required by theprocedure.

8 Remove the neutral density filter and close the transceiver.

9 The message ENTER when done is displayed. Press the ENTER key to complete the calibrationaudit.

1 Press the MAINTENANCE key for 2 seconds to exit maintenance mode. The red LED will go out.Modbus communications are the restored.

Calibration Audit Method 2 (Modbus communications are maintained)

1 Press and hold the EXIT key for 5 seconds.

2 The zero reflector is driven into its working position. The displayed value should be 0.00 ± 0.010.Note that this is fractional Opacity, i.e. 100 % is shown as 1.00.

3 Open the transceiver housing by releasing two quick-release clamps, and swing the instrumentopen on its hinges.

4 Insert a calibrated neutral density filter into slot 1.

5 Read and record the displayed opacity value. The instrument should read a value within ±1.0 % ofthe calibration filter. Note that this value will be corrected for the Optical Path length Ratio(OPLR). If the OPLR is set to the default value of 0.5, then the displayed value should match thefilter opacity. If the OPLR is not 0.5, then calculate the corrected value using the formula givenbelow.

6 Remove the filter, and insert, read and record the values for the other filters in turn as required bythe procedure.

7 Remove the neutral density filter and close the transceiver.

8 Press and hold the Maintenance key unit the red LED illuminates (about 5 seconds.)

9 Press the MAINTENANCE key for 2 seconds to exit audit mode. The red LED will go out.

OPLR correction formulaRefer to section B2-4-3 for instructions on finding the OPLR for your instrument.

The filter opacity is given on the calibration certificate supplied with the calibration filter.

OPLR

1

opacity)filter - (1 -1 Reading Instrument =

65

B4.3 Re-calibration

It is recommended that every three years a genuine clear stack calibration of the instrument is performed. The re-calibration command is used in performing this operation. Re-calibration is also required if a calibration audit shows the instrument to be outside of acceptable limits. Please ensure that all optical surfaces are clean and the optical path is not obstructed before performing any calibration. Re-calibration must be carried out by a Land Instruments International Service Engineer or other competent person. If the flange to flange path length is altered (i.e. due to relocation of the instrument) contact Land Instruments International customer services for instrument pathlength setup advice. Re-calibration should be carried out under clear stack conditions or in a laboratory with the transceiver set to the correct flange-to-flange path length.If an automatic fail-safe shutter is used, you will need to ensure it stays open during the recalibration. To do this, disconnect the wires from the shutter to terminals 19 and 20 on the T-box and connect these wires together. Re-member to re-connect the wires to the appropriate terminals after the recalibration is complete.

1 Press and hold the Maintenance key for 3 seconds until the red LED illuminates.

2 Enter the password using the ↑ or ↓ keys and then press Enter. The default password is 10.

3 Select the Calibration: menu with the ↑ or ↓ keys from the main menu.

4 Press the 'ENTER' (↵) key. Scroll with the ↑ or ↓ keys until 'Re-calibrate' is displayed.

5 Press the 'ENTER' (↵) key. The display will show 'Clear path'. Ensure the measuring path between the Transceiver and Retro-Reflector is clear of any obstruction.

6 When the measurement path is clear press the 'ENTER' (↵) key again. The display will show 'Settling' while the clear path measurement is in progress, when complete the display will show '100% point'.

7 Block the beam ( if the instrument is mounted on the stack, then the simplest method for blocking the beam is to undo the two quick release clamps on the Transceiver and swing the unit open).

8 Press the ‘ENTER’ (↵) key when ready. The instrument will automatically continue and calculate the zero and span calibration check points. The display will indicate the progress of the re-calibration sequence. Once the re-calibration is complete, the Model 4500 MkII+ will exit to the ‘Re-calibration’ menu.

9 Unblock the beam on completion of the operation.

10 The Model 4500 MkII+ is now correctly calibrated. The M203 Clear Stack Simulator option (if used) requires re-calibration immediately after re-calibration of the instrument.

11 Press and hold the Maintenance key for 1 second until the red LED switches off. The instrument is now is normal ‘RUN’ mode.

CAUTIONDo not attempt to move the zero point reflector by hand. The precision gearbox will be irreparably damaged.

Whenever the Land Instruments International Service Department is contacted regarding problems with an instrument, please have available information on the instrument type and serial number. This will enable the department to respond more accurately and efficiently.



66

B4-4 Isokinetic Calibration

The Model 4500 MkII+ measures the opacity of dust and smoke emissions. As explained in the Referencemanual, this value is related to the dust density in the stack, through the Beer-Lambert law (see sectionC1-2). In order to measure the dust density, it is necessary to know the Dust Gain (parameter 'k'),which relates optical density to dust density. Dust Gain is found by comparing with the measuredOptical Density/Dust Density found by an isokinetically sampled dust measurement.

The Model 4500 MkII+ is designed to be easily calibrated relative to an isokinetic sample. Two methodsmay be used, depending on whether the instrument is to be calibrated relative to a single sample, ormultiple samples. A single sample is simple to collect and analyse, but more often a series ofmeasurements are taken under different load conditions or at different points across the diameter ofthe stack. This method gives a more accurate representation of the overall dust burden in the stack.


67

Setting the Dust Gain value (single gravimetric value)

The Model 4500 MkII+ menu program contains a particularly simple method for calibrating the DustGain parameter against a single isokinetic sample. When preparations for doing an isokinetic sampleare in place, press the Maintenance key for 3 seconds until the LED is illuminated. Enter the passwordusing the ↑ or ↓ keys and then press Enter. The default password is 10. The system is unlocked andallows parameter access.

1. Select CALIBRATION: Isokinetic Cal: Acquire.

2. The display will show 'Start Isokinetic'.

3. Press 'ENTER' (↵↵↵↵↵) key at the same time as the isokinetic sampling period is started.

4. The display will now show ' End Isokinetic'.

5. Press 'ENTER' (↵↵↵↵↵) key at the end of the isokinetic sampling period.

6. The Model 4500 MkII display will show the average optical density value measured during theisokinetic sampling period. This value is stored in the memory of the Model 4500 MkII+ untilanother isokinetic sampling sequence begins.

7. Press and hold the Maintenance key for 1 second to return to 'Run' mode.

8. When the isokinetic sample has been analysed, return to the User interface and select theCalibration: Isokinetic Cal: calculate function. Use the ↑ or ↓ keys to input the measured dustvalue, then press 'ENTER' (↵↵↵↵↵) key. The Model 4500 MkII+ will then calculate the Dust Gainvalue using the previously stored average optical density value.

NOTE

The method described above can also be applied to multiple isokinetic samples: Choose'Start isokinetic' at the beginning of the first sample and 'End isokinetics' at the completion ofthe final sample. Once the samples have been analysed, calculate the mean dust value andinput this into the Model 4500 MkII+. This is a less accurate method than that specifically formultiple isokinetic samples, which should be used in critical applications.


68

Average OD0.037

Setting the Dust Gain value (multiple isokinetic samples)

1. When preparations for doing an isokinetic sample are in place, press the Maintenance key for3 seconds until the LED is illuminated. Enter the password using the ↑ or ↓ keys and thenpress Enter. The default password is 10. The system is unlocked and allows parameteraccess.

2. Select the CALIBRATION: Isokinetic Cal: Acquire function.

3. The display will show 'Start Isokinetic'.

4. Press 'ENTER' (↵↵↵↵↵) key at the same time as the isokinetic sampling period is started.

5. The display will now show ' End Isokinetic'.

6. Press 'ENTER' (↵↵↵↵↵) key at the end of the isokinetic sampling period.

The Model 4500 MkII+ display will show the average optical density value, measured during theisokinetic sampling period.

7. Write down the sample number and the average O.D. value.

IMPORTANT

A written record of all the O.D. values is essential.The Model 4500 MkII+ will overwrite this value when the next sample is taken.

8. Repeat the sequence for each isokinetic sample.


69

Isok

inet

ic D

ust M

easu

rem

ent

When all the samples have been analysed gravimetrically, it will be possible to plot a graph of dustdensity against average optical density for each of the samples. Plot a 'best fit' straight line passingthrough the origin as shown below. The gradient of this line is the Dust Gain value for your application.

1

2

34

200

150

100

50

0

0.05 0.10 0.15 0. 200.000.125

4500 MkII+ Optical Dust Value

Graph of Isokinetic Dust Measurement v 4500 MkII+ Optical Density Value

The Dust Gain value must now be input into the Model 4500 MkII+ using the setup menu in the Userinterface.

1. Choose SETUP: Miscellaneous: Dust Gain.

2. Press 'ENTER' (↵↵↵↵↵) key. Use the ↑ or ↓ keys to store.

3. Press and hold the Maintenance key for 1 second return to the 'Run' mode.

The Model 4500 MkII+ is now correctly calibrated for dust measurements.


70

B4-5 M203 Clear Stack Simulator

Checklist

The M203 Clear Stack Simulator System (Part number 703.902) contains the following:

M203 Clear Stack SimulatorSpare Apertures for M203 SimulatorSpare Apertures for Dust Span FilterSpare Apertures for Dust Zero ReflectorHexagon Keys

M203 Clear Stack Simulator System

Spare Apertures forDust Span Filter

Spare Apertures forM203 Simulator

Spare Apertures forDust Zero Reflector

Hexagon Keys

M203 Clear StackSimulator

Unused Slot


71

The instrument serial number and pathlength are printed on the carry case label. It is important thatthe M203 is only used with the instrument it has been calibrated with. Please ensure the plantinstallation location (i.e. Stack 1) is written on the carry case label before placing the clear self-adhesive label (Provided by Land Instruments International) over the top of the carry case label forprotection.

M203 CLEAR STACK SIMULATOR

M203 Carry Case Label


72

Fitting the Simulator

The M203 Clear Stack Simulator (Part Number 703.902) is used during the Re-calibration routine whentrue clear stack conditions are unobtainable. The Simulator should be fitted, as described below, when'Clear path' is displayed by the instrument (see Re-calibration). Follow the steps below, being carefulNOT to move the sliding adjusting plate on the back of the Simulator.

1. The User interface display should read 'Clear path' (see Re-calibration).

2. On the Transceiver undo the two quick release clamps and swing the unit open.

3. Remove the 5 crimp connectors from below the Automatic Zero Point Assembly. Make a note ofthe orientation of the wiring for reconnection.

CAUTION

Do not attempt to ROTATE the zero point reflector by hand. The precision gearboxwill be irreparably damaged. See section B4-1 for identification.

4. Undo the 2 socket head screws using the 5 mm hexagonal (Allen) key supplied and removethe Automatic Zero Point Assembly. Store in safe place until required for normal running ofinstrument.

Continue to step 5.

Opacity: 0%Clear Path↵↵↵↵↵↵↵↵↵↵CALIBRATION

Opacity: 0%Re-Calibrate:

5 CrimpConnectors


73

5. Check that the serial number of the instrument corresponds to the number marked on the Simulator.

6. Offer up the Simulator and tighten the two 5mm Allen bolts as shown below.

M203 Clear Stack Simulator

M5 Allen Bolt

Sliding Adjusting Plate

M5 Allen Bolt


74

↵↵↵↵↵Opacity: 0%Clear Path

Opacity: 0%100% point

Opacity: 0%Re-cal complete↵↵↵↵↵Opacity: 0%

100% point

7. On the User interface press the ENTER key and wait for the display to read '100% Point'.

8. At the Transceiver undo the 2 socket head screws and remove the Simulator. Store theSimulator in the carry case provided until required for Re-calibration.

9. Offer up the Automatic Zero Point Assembly and tighten the 2 socket head screws.

10. Attach the 5 crimp connectors in the same orientation as previously noted.

11. The instrument is now ready to perform 100% point calibration.

12. Always replace the Automatic Zero Point Assembly before pressing the ENTER key for 100%point calibration. The motor that lifts the reflector activates immediately after the 100% pointcalibration.

IMPORTANT

The instrument will display a fault if the Automatic Zero Point Assembly is not replacedbefore continuing with the 100% point calibration.

M203 Clear Stack Simulator Carry Case


75

B4-6 M203 Clear Stack Simulator Calibration

All instruments are shipped out from the factory configured to customers' requirements. Re-calibrationof the M203 Clear Stack Simulator is required immediately after re-calibration of the instrument. It isrecommended that re-calibration is performed every three years or if a Calibration Audit shows theinstrument to be outside of acceptable limits. Please ensure that all optical surfaces are clean and theoptical path is not obstructed before performing any calibration.

If the flange to flange path length is altered (i.e. due to relocation of the instrument) contact LandInstruments International customer services for instrument pathlength setup advice.

IMPORTANT

Re-calibration should be carried out under clear stack conditions or in a laboratory with theTransceiver set to the correct flange-to-flange path length.The M203 Clear Stack Simulator should be re-calibrated following a genuine re-calibration of the instrument only (recommended every three years).

If in any doubt about these instructions, please contact Land Instruments International CustomerServices Department before proceeding. Take care when handling the reflective surfaces as they caneasily be scratched or made dirty.

CAUTION


Immediately after a genuine clear stack re-calibration perform the following steps for re-calibration ofthe M203 Clear Stack Simulator.

1 Press the Maintenance key for 3 seconds until the LED is illuminated. The system isunlocked and allows parameter access.

2 Enter the password using the ↑ or ↓ keys and then press Enter. The default password is 10.

3 Undo the two quick release clamps on the Transceiver, swing open the case and identify theAutomatic Zero Point Assembly

Continue to step 3.


76

Automatic Zero Point Assembly

3 Remove the Automatic Zero Point Assembly by undoing the two socket head screws.

4 Fit the M203 Clear Stack Simulator as described in the previous section.

5 At the User interface set the instrument to display negative values (see section C4-4) andthen observe the measurement reading with the M203 Clear Stack Simulator still attached.

6 Loosen the locking nut on the sliding adjusting plate and slide the plate until the instrument ismeasuring zero.

If the instrument cannot be set to measure zero opacity by adjusting the sliding adjuster on the back ofthe M203 Simulator it is necessary to change the aperture and grating that cover the reflective surface.

Select an aperture plate and grating using the table in Appendix A-1. Identify the B value correspondingto the aperture plate and grating in use (i.e. Aperture Plate D, Grating 2 corresponding B value 0.94).

If the black wedge shape on the front of the sliding adjuster on the M203 Simulator completely coversthe reflective surface then replace the current aperture plate and grating with the ones corresponding tothe next highest B value (i.e. Next highest B value 0.97 corresponding aperture plate C and grating 2).

If the black wedge shape on the front of the sliding adjuster on the M203 Simulator cannot be seen thenreplace the current aperture plate and grating with the ones corresponding to the next lowest B value(i.e. Next lowest B value 0.91 corresponding aperture plate E and grating 2).

Continue to step 7.


77

7 Lock the sliding adjusting plate in place.

IMPORTANT

The M203 Clear Stack Simulator once calibrated to an instrument should not be adjustedunless undergoing another re-calibration.

8. Undo the 2 socket head screws and remove the Simulator. Store the Simulator in the carrycase provided until required for Re-calibration.

9. Offer up the Automatic Zero Point Assembly and tighten the 2 socket head screws (5mm).

10. Attach the 5 crimp connectors in the same orientation as previously noted.

11. Close the Transceiver casing and press the Maintenance key for 1 second until the LEDswitches off. The instrument is now in RUN mode.

The instrument is now ready for normal operation.


78

B4-7 Zero Point Reflector Adjustment

All instruments are shipped out from the factory configured to customers' requirements.

The following procedures should only be necessary if the optical path length or theopacity standard has been changed.

If in any doubt about these instructions, please contact Land Instruments International CustomerServices Department before proceeding. Take care when handling the reflective surfaces as they caneasily be scratched or made dirty.

CAUTION


1. Remove the instrument from the stack and set up on test stands positioned at the correctflange to flange distance.

2. Press the Maintenance key for 3 seconds until the LED is illuminated. The system isunlocked and allows parameter access.

3. Perform a Re-calibration (see section B4-3).

4. Display and make note of the 'B' value on the Parameters menu (see section B2-4).

5. On the table in Appendix A find the 'B' value (or the nearest lower value). The value mayoccur in two columns. Select the Aperture Plate (horizontally) and the Grating (vertically)relating to the 'B' value.

6. Install the selected Aperture Plate and Grating as described in this section.

Continue to step 7.


79

7. Repeat the Re-calibration procedure (see section B4-3).

8. Display the parameter 'B' on the Parameters menu (see section B2-4).

9. The 'B' value should now be within the range 0.95 to 1.05. The zero point reflector is readyfor normal use. If the 'B' value is not within the range 0.95 to 1.05 then it will be necessary tochange the aperture and grating as described below.

If the 'B' value is less than 0.95 use the Aperture Plate belowthe previously selected aperture plate in the table.

If the 'B' value is greater than 1.05 use the Aperture Plate abovethe previously selected aperture plate in the table.

10. Repeat the Re-calibration as before and check the 'B' value again. Repeat steps 6 to 10 ifrequired.


80

Zero Point Reflector, Aperture Plate and Grating Installation

A range of apertures and gratings for the Zero Point Reflector are provided with the instrument.

CAUTION


Removing the Zero Point Reflector

1

2

2

3

Zero Point Reflector

Key.

1. Zero Point Reflector2. 2 M3 Allen head screws3. Automatic Zero Point Assembly

1. Undo the two quick release clamps on the Transceiver and swing the unit open, revealing theAutomatic Zero Point Assembly.

2. Undo the 2 M3 socket head screws (2) (as illustrated above) holding the Zero Point Reflectorin place and remove it from the Automatic Zero Point Assembly using a 2.5mm Allen Key.

3. To replace, reverse the procedure.


81

Installing an Aperture Plate and Grating

1

2

3

4

5

Zero Point Reflector Variable Aperture Assembly

Key.

1. Zero Point Reflector Holder2. Grating3. Aperture Plate4. Reflector Plate5. 3mm Allen head screws

1. Undo the 3 M3 socket head screws (5) using a 2.5mm hexagonal (Allen) key and remove theReflector Plate, Aperture Plate and Grating.

2. Identify the selected Aperture Plate and Grating as shown above.

3. Set the Aperture and Grating Plates into the recess, ensuring that the tabs on both are alignedwith the slot on the holder.

4. Locate the Reflector Plate and tighten the 3 socket head screws.

5. Refit the Zero Point Reflector on to the Automatic Zero Point Assembly as described previously.


82

B4-8 Upscale Span Filter Adjustment

U.S. Legislation requires that the instrument is periodically checked using an Upscale Calibration Valuethat is 150% to 190% of the applicable opacity standard. This is achieved using an Automatic SpanFilter. A range of gratings for the Span Filter are provided with nominal Opacities of 5%, 10%, 15%,20%, 28%, 36%, and 45%. The instrument is factory set with a span filter of 28%.

To install an alternative filter from the set provided, follow the procedure outlined below.

Removing the Span Filter

1. Ensure that the power to the instrument is switched off.

2. Undo the two quick release clamps on the Transceiver and swing the unit open, revealing theAutomatic Zero Point Assembly.

3. Undo the hinge pins (captive in the purge assembly) using a 5mm Allen key and lift theTransceiver away from the purge assembly.

4. Undo the sixteen M4 socket head screws holding the outer casing in place using a 3mmhexagonal (Allen) key and partly withdraw the casing.

NOTE

A Static protection wrist band should be worn at this point

5. Disconnect the Umbilical Klippon terminal strip and remove the outer casing.

Continue to step 6.


83

6. Undo the 2 flat head screws (accessible from underneath the Transceiver) holding the MicroProcessor Board in place (NOTE:- These screws are captive).

7. Disconnect the Klippon terminal strip connecting the Micro Board to the Main P.C.B.

8. Remove the Micro Processor Board.

CAUTION

Do not attempt to ROTATE the span filter by hand. The precision gearbox will beirreparably damaged. See section B4-1 for identification.

1

2

Span Filter Assembly

Key.

1. Span Filter2. 2 Allen head screws (3mm)

9. Undo the 2 M3 socket head screws (2) holding the Span Filter in place as shown above andremove it.

10. To replace, reverse the procedure.


84

Installing a Grating

1

2

3

Span Filter

Key.

1. Span Filter Holder2. Grating3. M3 Allen head screws

1. Undo the 3 M3 socket head screws (3) using a 2.5mm socket (Allen) Key and remove the oldgrating.

2. Locate the new grating (see the Span Filter Gratings table in Appendix A).

3. Refit the new grating using the 3 M3 socket head screws.

4. Locate the Span Filter onto the instrument as described previously.


85

C1 Theory of Operation and Application

C1-1 General Outline

When a beam of light crosses a medium containing smoke or dust particles, some of the light istransmitted and some is lost due to scattering. The fraction which is transmitted is called thetransmittance and the fraction which is lost is the opacity.

In the early days of emissions measurement, the opacity of the smoke leaving a stack was measuredby the Ringelmann method in which a trained observer makes a visual estimate of its appearance.

Modern methods for opacity measurement are far more sophisticated than the Ringelmann method,but many of the specifications relate back to the way the human eye sees smoke emissions. Thewavelength response of an opacity monitor must mimic that of the human eye. An instrument musthave a nearly photopic response. The Land Model 4500 MkII+ uses a high-intensity green LED lightsource to achieve this.


86

C1-2 Beer-Lamberts Law

The mathematical relationship between the light transmitted by a medium and the quantity of pollutantpresent is known as the Beer-Lambert Law and may be written;

τ = I = e -acL

Io

where: τ = TransmittanceIo

= Intensity of light into the medium (see 1 below)I = Intensity of light out of the medium (see 3 below)a = Attenuation Coefficientc = Concentration of PollutantL = Distance light beam travels through the medium (see 2 below)

1

2

3

Since opacity (Op) = 1 - τ , the above equation becomes:

(1 - Op) = e -acL or Op = 1 - e -acL

Note that the quantity c is the amount of dust in the optical path. Optical Density (or extinction) isdefined as;

OD = -log10

τ

= -acL/2.303

c = k x OD where k = -2.303aL

By comparing a series of optical density measurements with gravimetric dust measurements taken atthe same time, it is possible to determine the value of k.


87

C1-3 Optical Pathlength Ratio (OPLR)

The last item that we need to address is the fact that opacity monitors may not always be mounted atthe exit of a stack. Since the Ringelmann observer always views opacity at the exit of a stack, wemust also introduce a factor to correct for the change in pathlengths between the measurement andexit diameters of the stack. It should also be pointed out at this time that the Land Model 4500 MkII+

Dust & Opacity Monitor is a double pass instrument. This means that the light beam crosses themedium twice and hence experiences twice the amount of absorption as illustrated below. This mustalso be corrected in our system.

The Optical Path Length Ratio (OPLR) is the ratio between the diameter of the stack exit and thedistance travelled through the stack gases by the beam. For a double-pass instrument like the Model4500 MkII, the OPLR is equal to half the PLCF i.e.

The Path Length Correction Factor (PLCF) is only relevant for Opacity measurements. It is the ratiobetween the diameter of the stack exit and the diameter of the stack at the point where the instrumentis installed. For a parallel stack, the PLCF is 1.0. For a tapering stack which is narrower at the exitthan the base, the PLCF is less than 1.0.

OPLR = PLCF2

The parameter used in the Model 4500 MkII+ is the OPLR, and it has a default value of 0.5, correspondingto a parallelsided duct. In early instruments, this parameter is labelled as PLCF.

1

2

3

45

Key1. Light source l

o4. Reflector

2. Detector 5. Beam Splitter3. Distance light beam passes through medium (L)

Double Pass System


88

We can use the previous equations to calculate the opacity at the stack exit, if we define the pathlengthcorrection factor (PLCF);

PLCF = Le

Lm

where: Le

= the exit pathlengthL

m= the measurement pathlength

OPLR = PLCF2

Ope

= 1 - 10 -OD × OPLR


89

C1-4 Examples of Different Optical Path Length Correction Ratios (OPLR)

Straight stack.Measurement pathlength and exit pathlength are equal.

PLCF = 1.00, OPLR = 0.50

Example 1

Straight stack, monitor on narrow duct.Measurement pathlength is less than exit pathlength.

PLCF > 1.00, OPLR >0.50

Example 2

Stack narrows towards exit.Measurement pathlength is greater than exit pathlength.

PLCF < 1.00, OPLR <0.5

Example 3


90

C2 Requirements for Environmental Legislation

The Model 4500 MkII+ meets or exceeds the requirements of U.S. 40CR60 AppB PS1 and ASTMStandard Practice D6216.

It has been approved be TÜV Rhineland in Germany for installations under 13th BImSch V and TALuft, Report No 936/808016/A.


91

C3 Physical Principles

C3-1 General Description

The Land Instruments International Model 4500 MkII+ Continuous Opacity Monitoring System (COMS)measures opacity by shining a light beam through flue gases. An internal microprocessor calculatesopacity, dust density and other parameters. The instrument comprises the following parts: The Transceiverwhich contains all of the optical and electrooptic components; the Retro-Reflector containing a plastic orglass retro-reflector; the Termination Box where the customer terminations are located; and the air purgesystem. An optional data display Control Room Unit is available.



TerminationBox

Transceiver

Retro-Reflector


92

C3-2 Principle of Operation

The Land Model 4500 MkII+ is intended to be the most accurate and reliable opacity monitor available.It uses a high-intensity green LED source, very low noise electronics and a sophisticated normalisationsystem to minimise calibration drift. The LED is electronically modulated at a frequency of 3kHz inorder to reduce noise and eliminate errors due to background light. Electronic modulation eliminatesthe need for a mechanical chopper and so the only moving parts are the motors used in the calibrationsystem. These motors have a very low duty cycle and are very reliable.

1 1

1 2 8 9

3 6 7 4

10

5

Transmissometer

1. LED light source 7. Reference Detector2. Flood LED 8. Concave Mirror3. 50/50 Beam Splitter 9. Span Filter4. Collimating Lens 10. Zero Point Reflector5. Collimated Beam 11. Diffuser6. Measurement Detector

The Transceiver is illustrated above. Light from source LED1 (1) passes through the diffuser (12) andon to the 50/50 beamsplitter (3). The transmitted portion passes on to the lens (4) which projects awell-defined, collimated beam (5) across the measuring path to the distant Retro-Reflector. Lightreturned from the retro is focused by the lens (4) onto measurement detector

(6). The portion of light

originally reflected by the beamsplitter (3) falls on the concave mirror (8) which focuses it ontoreference detector (7). The opacity value can be calculated from the ratio of the signals on the twodetectors.

This is true only as long as long as the responsivity of the detectors (6 and 7) and the gain of their associatedelectronics remains constant. In practice, temperature variations and ageing of the components means that

11


93

this cannot be guaranteed. The Model 4500 MkII+ uses a novel method to compensate for such changesby using the flood LED (2) to flood both detectors (6 and 7) with light. Because it uses no focusing optics,there is no possibility of misalignment and so any relative change in sensitivity between detectors

(6 and

7) will lead to a change in the ratio of signals from LED2 (2). By alternating light sources (1) and (2) onceevery second, the normalisation procedure is effectively continuous.

The microprocessor performs the calculations required to perform the normalisation and toconvert the opacity measurement into optical density or dust density as required.

Calibration Check

The transmissometer periodically performs a two step calibration check. In the first step, a zero-pointreflector (10), mounted on the outside of the Transceiver is placed into the optical beam. In thesecond step, the span filter (9) is also placed in the light path. The monitor reads the difference inlight level between the current value and that established during the last clear stack calibration, andmakes a correction. The opacity value of the span filter (9) is shown on the calibration certificatewhich accompanies the instrument.


94

C4 User Interface

C4-1 Operational Structure

The operational structure of the Model 4500 MkII+ is basically made up of a menu spine containingfive menus FAULTS, CALIBRATION, SETUP, DISPLAY and PARAMETERS. Scroll through themenu spine using the ↑ and ↓ keys, once a menu has been selected press the ENTER (↵↵↵↵↵) key toaccess it. For the navigation purposes of this manual, wherever an asterisk (*) is shown press theENTER (↵↵↵↵↵) to access a further sub-menu. Pressing EXIT returns the user to the previous menu.

Operation of the instrument should be carried out by an authorised, competent person only.Enter the password using the arrow keys and press Enter. The default password is 10.The menus available are explained in more detail in the this section.

Overview of Operational StructureAll menus marked * use a further sub-menu.

↵↵↵↵↵ ↵↵↵↵↵ ↵↵↵↵↵ ↵↵↵↵↵ ↵↵↵↵↵

or

FAULTS ↑↓ CALIBRATION ↑↓ SETUP ↑↓ DISPLAY ↑↓ PARAMETERS

Cal Check↑↓

Re-Calibrate*↑↓

IsokineticCal*↑↓

Cal Audit*↑↓

Manual Cal*↑↓

RecallFactory*

↑↓Cal Setup*

Outputs*↑↓

Alarms*↑↓

Miscellaneous*↑↓

Service

Top line*↑↓

Bottom line*

Faults: xx↵↵↵↵↵

Fail in Cal

Faults: 0 SO Zero Damper:↑↓ xx.xxSf ↑↓↑↓ FloodSm Damper: xx.xx↑↓ ↑↓Ro Measure↑↓ Damper: xx.xxRf ↑↓↑↓ Cal Damper:Rm xx.xx↑↓ ↑↓C OP1 Damper:X xx.xx

↑↓ ↑↓B OP2 Damper:

↑↓ xx.xxG ↑↓↑↓ PLCF: xx.xxQ ↑↓↑↓ Last Cal: xx.xx

Dust Gain: ↑↓xx.xx Zero Comp:

↑↓ xx.xxDust Offset: ↑↓

xx.xx Isokinetic OD:↑↓ xx.xx

↑↓Version: xx.xx

eg


95

↵↵↵↵↵

↵↵↵↵↵

or

Opacity: 0%Faults: 0

Opacity: 0%Faults: 1

Opacity: 0%Faults: Fail in cal

FAULTS

C4-2 Faults Screens

FAULTS

On selection of FAULTS from the menu spine, press the ENTER (↵↵↵↵↵) key.

No Faults Detected

If no faults are detected by the software, the display will show ' Fault: 0'and the user may return to the menu spine by pressing the EXIT key.

Faults Detected

However, if a fault or faults are detected then the display will show'Faults: xx' the xx denoting the number of faults detected.

Press the ENTER (↵↵↵↵↵) key again to display a description of the fault/faults. See the Fault Finding section in this manual. The user may thenreturn to the menu spine by pressing the EXIT key.


96

C4-3 Calibration Screens

The instrument is checked and calibrated using the calibration menu. On selection of CALIBRATIONon the menu spine, press the ENTER' (↵↵↵↵↵) key. The calibration menu contains seven sub menus:

Calibration Check Manual CalibrationRe-Calibration Recall FactoryIsokinetic Calibration Calibration SetupCalibration Audit

Illustrated below is the operational structure for the Calibration menu. Each sub-menu found withinthe Calibration menu is explained in more detail within this section.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

Clear Path ↵↵↵↵↵ Settling Clear Path OK 100% point ↵↵↵↵↵ Settling 100% Opacity OK Running in Zero Balance OK

Running in Span Settling Running out Re-cal complete

Acquire↑↓

Calculate

Start Isokinetic ↵↵↵↵↵ End Isokinetic ↵↵↵↵↵ Isokinetic O.D.

Meas. Dust x.xx ↑↓ Meas. Dust o.o to 99999

Running in ↵↵↵↵↵ When Done ↵↵↵↵↵ Running out

C: xxxx ↵↵↵↵↵ x: x.xxx ↵↵↵↵↵ Running in B: x.xxx ↵↵↵↵↵ Running out B 1.000

Restore Factory ↵↵↵↵↵ YES ↵↵↵↵↵ Factory Values

Interval x.xxh↑↓

Time to next cal.xxh xmins

Interval x.xxh

Time to next cal. ↵↵↵↵↵

Time to next cal.xxh xmins xxh xmins

Cal Check↑↓

Re-Calibrate↑↓

Isokinetic Cal↑↓

Cal Audit↑↓

Manual Cal↑↓

RecallFactory

↑↓Cal Setup

(A Zero and Span Check is carried out taking approximately 3 minutes)

CALIBRATION


97

CALIBRATION CHECK (CAL CHECK)

On selection press the ENTER' (↵↵↵↵↵) key. The monitors will perform azero and span check. This will take approximately three minutes tocomplete. During the first half of this period a zero point reflector isautomatically placed into the sight path of the system. During thesecond half of this period the zero point reflector remains in place and aspan filter is automatically placed before it into the sight path.

RE-CALIBRATE

On selection of Re-Calibrate press the ENTER' (↵↵↵↵↵) key to initiate the re-calibration sequence. This sequence is easily followed via the sub-menudescribed below.

(Clear Stack Calibration)

This menu provides a clear stack calibration sequence. On selectionpress the ENTER (↵↵↵↵↵) key. The display will show 'Clear path'. Ensurethe that no obstruction, dust, gases are present in the sight paththat would effect a zero opacity condition. When the clear stackconditions are satisfactory, press the ENTER (↵↵↵↵↵) key to continue.

100% Point Calibration

The next sequences follow automatically until '100% point' is displayed.This is a request for a 100% opacity condition to be set up. The simplestway to achieve this is to unclip the Transceiver case and swing it open.This breaks the line of sight path to the Retro-Reflector and creates an100% opacity condition. When ready, press the ENTER' (↵↵↵↵↵) key.

The rest of the sequence follows automatically until the display shows'Re-cal complete'.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

Opacity: 0%Cal. Check:

Opacity: 0%Re-Calibrate:

Opacity: 0%Clear Path

Opacity: 0%100% point

Opacity: 0%Re-cal complete


98

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

Isokinetic CalAcquire:

Isokinetic CalIsokinetic O.D.: x.xx

Isokinetic CalEnd Isokinetic

Isokinetic CalStart Isokinetic

↵↵↵↵↵

Opacity: 0%Isokinetic Cal

Acquire↑↓

Calculate

ISOKINETIC CALIBRATION

This procedure is done in conjunction with an isokinetic sample orsamples, being taken at the same time and under the same conditions asthe measurements being taken by the Model 4500 MkII+.

On selection press the ENTER (↵↵↵↵↵) key. Two further sub-menus areavailable Acquire and Calculate. Select the required sub-menu usingthe ↑ and ↓ keys.

Acquire (Isokinetic Calibration sub-menu)

From the Isokinetic Calibration sub-menu press the ENTER' (↵↵↵↵↵) key, aspreviously described, to display 'Acquire'. This screen allows access tothe acquisition mode. Press the ENTER (↵↵↵↵↵) key again and thereafterthe next two steps. The user can follow the subsequent, selfexplanatory start/stop displays to be timed to occur instantaneouslywith the isokinetic sampling.

Finally the display shows the Average O.D. (Optical Density) value readby Model 4500 MkII+, this is automatically stored by the instrument. (Waitfor isokinetic sample results).


99

Calculate (Isokinetic Calibration sub-menu)

Using the ↑ or ↓ keys when 'Acquire' is displayed to access the Calculatesub-menu. Press the ENTER' (↵↵↵↵↵) key to select 'Meas. Dust x.xx (noticethe underlined character) and enter the isometric dust value (whenavailable) using the ↑ and ↓ keys, provided by the isokinetic sampling.

For multiple isokinetic samples repeat the single sample sequence forthe number of required times and record the results. Draw a graph fromthe readings. For details see the section on Dust Calibration methods.

CALIBRATION AUDIT (CAL AUDIT)

This sequence is provided so that verification by an independent checkusing external audit filters can be carried out. On selection of Cal. Auditpress the ENTER' (↵↵↵↵↵) key to insert the zero reflector. The wordsRunning in are displayed briefly.

Press the ENTER' (↵↵↵↵↵) key when the word done' is displayed. Thewords Running out will be displayed briefly.

Press the ENTER' (↵↵↵↵↵) key. to end the 'Cal Audit' sequence.

Press the EXIT key to return to the Calibration menu.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

Isokinetic CalCalculate:

Isokinetic CalMeas. Dust: x.xx

Opacity 0%Cal. Audit

Cal. AuditDone

Opacity 0%Cal. Audit


100

MANUAL CALIBRATION (MANUAL CAL)

This sequence is not recommended to be followed by the user. The manualcal sequence requires values to be entered manually. Re-calibrate is amore accurate operation. This provision is of more practical use to aservice engineer.

FACTORY SETTINGS (RECALL FACTORY)

Provides a simple method to return the Model 4500 MkII+ to its factorycalibration state. This may be helpful e.g. where a re-calibrate sequencehas not been successful. On selection of Recall Factory from theCalibration menu press the ENTER' (↵↵↵↵↵) key. The display reads RestoreFactory, press the ENTER' (↵↵↵↵↵) key again and then select YES or NOusing the ← or → key.

Press the ENTER' (↵↵↵↵↵) key whilst YES is displayed to return theinstrument back to its factory settings. Press the ENTER' (↵↵↵↵↵) key whilstNO is displayed to return to the Recall Factory screen on theCalibration menu.

CALIBRATION SETUP (CAL SETUP)

On selection of the Cal. Setup sub-menu press the ENTER (↵↵↵↵↵) key. Toset the time interval between calibrations (Interval x.xxh) and the timethat the instrument will wait before performing the first calibration (Timeto next cal). These two options appear as a sub-menu and are scrolledby pressing the ↑ or ↓ keys.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

→←

↵↵↵↵↵

Opacity 0%Manual Cal.

Opacity 0%Restore Factory: Yes

Opacity 0%Restore Factory: No

Opacity 0%Restore Factory

Opacity 0%Recall Factory

Opacity 0%Factory Values

Opacity 0%Cal. Setup

Interval↑↓

Time to next cal.


101

Interval

On selection of Interval x.xxh press the ENTER' (↵↵↵↵↵) key (notice theunderlined x). Use the ↑ and ↓ keys to select the time interval (in hours)between automatic calibrations. The default setting is 24 hours.

Once a time interval has been selected it is set by pressing the EXITkey which returns the display to the Cal Setup screen.

NOTE

If 0 (zero) is entered for the cal interval, the internal automaticcalibration facility is disabled. Calibration check sequencescan be initiated by placing a contact closure across terminal 36and 37 inside the Termination Box or via Modbus.

Time to Next Calibration

On selection of Time to next cal press the ENTER' (↵↵↵↵↵) key (notice theunderlined x next to the h on the bottom line). The time interval beforethe first calibration can now be set.

First select the hours using the ↑ and ↓ keys and then press ENTER'(↵↵↵↵↵) (notice the underlined x has moved under character next to mins).

Use the ↑ and ↓ keys again to select the minutes required. Once a timeinterval has been selected it is set by pressing the ENTER' (↵↵↵↵↵) key.

Press the EXIT key to return the display to the Cal Setup screen.

↵↵↵↵↵

↑↓

↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

↑↓

Time to next cal.xxh xxmins

Cal. SetupInterval: 24h



Time to next cal.xx h xx mins

Time to next cal.2 h xx mins

Time to next cal.2 h 10 mins


102

C4-4 Setup Screens

The instrument is made ready for operation using the Setup menu. On selection of Setup on themenu spine press the ENTER' (↵↵↵↵↵) key. The setup menu contains four sub-menus:

Outputs MiscellaneousAlarms Service

Illustrated below is the operational structure for the Calibration menu. Each sub-menu found withinthe Calibration menu is explained in more detail within this section.

All menus marked * use further sub-menus.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

SETUP

Outputs↑↓

Alarms↑↓

Miscellaneous↑↓

Service

Output 1* ↑↓ Averaging 1* ↑↓ Output 2* ↑↓ Averaging 2*

Alarm 1↑↓

Alarm 2

AL1 Type*: O.D. ↑↓ AL1 Trip*: 0.00 ↑↓ Delay*: 5s

AL1 Type*: O.D. ↑↓ AL1 Trip*: 0.00 ↑↓ Delay*: 5s

Align* ↑↓ Opac. disp*: % ↑↓ O/P1 Range*: 4-20 ↑↓O/P2 Range*: 4-20 ↑↓ Dust Gain*: x ↑↓ Dust Offset*: x ↑↓ OP0 Limit*

↑↓ Station number*: x ↑↓ Link*: Not fitted ↑↓ Display -ve: No

Entry Code: xx


103

Setup Output Screens (Outputs)

Two signal outputs are available to the user and are setup using the Output 1 and Output 2 sub-menus respectively. The time period used for block averaging may be set independently for eachoutput using the Average 1 and Average 2 sub-menus.

Illustrated below is the operational structure for the Output 1 and Averaging 1 sub-menus. Theoperational structure for Output 2 and Averaging 2 are identical. Both Output 1 and Averaging 1sub-menus are explained in more detail within this section.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

→←

↵↵↵↵↵ ↵↵↵↵↵ ↵↵↵↵↵↵↵↵↵↵

↵↵↵↵↵

SETUP

Outputs↑↓

Alarms*↑↓


Service*

Output 1 ↑↓ Averaging 1 ↑↓ Output 2* ↑↓ Averaging 2*

Averaging: Offxh xm xs


Averaging: Onxh xm xs

↵↵↵↵↵Averaging: Onxh xm xs

↵↵↵↵↵Averaging: Onxh xm xs

Dust↑↓

Range: x.x↑↓

During Cal.:Track

Cal. Drift↑↓

Range: x.x↑↓

During Cal.:Track

Optical Density↑↓

Range: x.x↑↓

During Cal.:Track

Constant Current↑↓

Const. Current:x.x↑↓

During Cal.:Track

Opacity ↑↓ Dust ↑↓ Constant Current ↑↓ Cal. Drift ↑↓ Optical Density

Opacity↑↓

Range: x.x↑↓

During Cal.:Track


104

SETUP OUTPUTS (OUTPUT 1)

The first customer output is set from this menu. On selection press theENTER' (↵↵↵↵↵) key. There are now two further options to set for each ofthe following (gain access as described in the earlier in this section):

Opacity, Dust, Constant Current, Calibration Drift, Optical Density.

Opacity

On selecting Opacity press the ENTER' (↵↵↵↵↵) key (notice no underlining).Two options are available, Range (Opacity range is in fractional opacity;i.e. 0.5 is 50% opacity) and During Cal. These two options are scrolledby pressing the ↑ and ↓ keys and can be selected by pressing theENTER' (↵↵↵↵↵) key to reveal an underlined character.

Range of Output 1 (Range)

On selecting Range x.x press the ENTER' (↵↵↵↵↵) key as described inOpacity above until an underlined character appears. Select therequired value by pressing the ↑ and ↓ keys. Press the ENTER' (↵↵↵↵↵) keyagain to return the display to Range x.x (no underlined characters) asillustrated.

Track or Hold output during calibration (During Cal)

On selecting the During Cal: Track display, press the ENTER' (↵↵↵↵↵) keyas previously described in Opacity, until an underlined characterappears.

Select the required value by pressing the ← and → keys. Press theENTER' (↵↵↵↵↵) key again to return the display to During Cal: Track orDuring Cal: Hold (no underlined characters) as illustrated.

Press the EXIT key to return the display to Output 1

↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↑↓

↵↵↵↵↵

Output 1During Cal.: Hold

Output 1Opacity

Output 1Range: x.x

Output 1Range: x.x

Output 1During Cal.: Track


Output 1Range: x.x

OutputsOutput 1


105

Dust.

On selecting Dust press the ENTER' (↵↵↵↵↵) key (notice no underlining).Two options are available, Range (Dust range is in mg/m3) and DuringCal. These two options are scrolled by pressing the ↑ and ↓ keys andcan be selected by pressing the ENTER' (↵↵↵↵↵) key to reveal an underlinedcharacter.


On selecting Range x.x press the ENTER' (↵↵↵↵↵) key as described inDust above, until an underlined character appears. Select the requiredvalue by pressing the ↑ and ↓ keys. Press the ENTER' (↵↵↵↵↵) key again toreturn the display to Range x.x (no underlined characters) as illustrated.


On selecting During Cal: Track press the ENTER' (↵↵↵↵↵) key as describedin Opacity above, until an underlined character appears. Select therequired value by pressing the ← and → keys. Press the ENTER' (↵↵↵↵↵)key again to return the display to During Cal: Track or During Cal:Hold (no underlined characters) as illustrated.


↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↑↓

Output 1Dust

Output 1Range: x.x

Output 1Range: x.x



Output 1Range: x.x



106

Constant Current

Constant Current is normally used to calibrate the users data acquisitionsystem. On selecting Constant press the ENTER' (↵↵↵↵↵) key (notice nounderlining). Two options are available, Constant Current and DuringCal. These two options are scrolled by pressing the ↑ and ↓ keys andcan be selected by pressing the ENTER' (↵↵↵↵↵) key to reveal an underlinedcharacter.

Constant

On selecting Constant press the ENTER' (↵↵↵↵↵) key as described inConstant Current above, the display changes to Constant x.xmA (noticethe underlined character. Select the required value by pressing the ↑and ↓ keys. Press the ENTER' (↵↵↵↵↵) key again to return the display toConstant x.x (no underlined characters) as illustrated.


↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↑↓

Output 1Output 1

Output 1Constant Current

Output 1Constant : x.xmA



Output 1Constant Current



107

Calibration Drift (Cal. Drift)

On selecting Cal. Drift press the ENTER' (↵↵↵↵↵) key (notice no underlining).Two options are available, Range and During Cal. These two optionsare scrolled by pressing the ↑ and ↓ keys and can be selected by pressingthe ENTER' (↵↵↵↵↵) key to reveal an underlined character. Cal. Drift displaysany drift that may occur between calibrations.


On selecting Range x.x press the ENTER' (↵↵↵↵↵) key as described inCalibration Drift above, until an underlined character appears. Selectthe required value by pressing the ↑ and ↓ keys. Press the ENTER' (↵↵↵↵↵)key again to return the display to Range x.x (no underlined characters)as illustrated.


On selecting During Cal: Track press the ENTER' (↵↵↵↵↵) key as describedin Calibration Drift above, until an underlined character appears. Selectthe required value by pressing the ← and → keys. Press the ENTER'(↵↵↵↵↵) key again to return the display to During Cal: Track or During Cal:Hold (no underlined characters) as illustrated.


↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↑↓

Output 1Cal. Drift

Output 1Range: x.x

Output 1Range: x.x




Output 1Range: x.x


108

Optical Density (O.D.)

On selecting O.D. press the ENTER' (↵↵↵↵↵) key (notice no underlining).Two options are available, Range (O.D. range is in units of OpticalDensity) and During Cal. These two options are scrolled by pressing the↑ and ↓ keys and can be selected by pressing the ENTER' (↵↵↵↵↵) key toreveal an underlined character.


On selecting Range x.x press the ENTER' (↵↵↵↵↵) key as described inO.D. above, until an underlined character appears. Select the requiredvalue by pressing the ↑ and ↓ keys. Press the ENTER' (↵↵↵↵↵) key again toreturn the display to Range x.x (no underlined characters) as illustrated.


On selecting During Cal: Track press the ENTER' (↵↵↵↵↵) key as describedin O.D. above, until an underlined character appears. Select the requiredvalue by pressing the ← and → keys. Press the ENTER' (↵↵↵↵↵) key againto return the display to During Cal: Track or During Cal: Hold (nounderlined characters) as illustrated.


↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

→←

↵↵↵↵↵

↑↓

↑↓

Output 1O.D.

Output 1Range: x.x

Output 1Range: x.x




Output 1Range: x.x


109

SETUP OUTPUTS (AVERAGING 1)

On selection of Averaging 1 from the Output 1 menu, as describedpreviously, press the ENTER' (↵↵↵↵↵) key. The display changes toAveraging: Off on the top line and the averaging time intervals aredisplayed on the bottom line. The averaging option sets the time intervalat which the outputs will be made. It is possible to switch the averagingoption on or off and to alter the time interval required.

Altering the Averaging Settings

Before altering the averaging settings, make sure the O is underlinedand then press the ENTER' (↵↵↵↵↵) key. Set the averaging to On or Off asappropriate by pressing the ← or → keys and then press the ENTER'(↵↵↵↵↵) key to alter the time interval. Press the ↑ and ↓ keys to select anappropriate number of hours and then press the ENTER' (↵↵↵↵↵) key.Continue using the ↑ and ↓ keys to select appropriate values for theminutes and seconds. Each time press the ENTER' (↵↵↵↵↵) key to movebetween hours , minutes and seconds.

Press the EXIT key to return to the Averaging 1 display.

SETUP OUTPUTS (OUTPUT 2)

The settings for signal output 2 are identical to signal output 1. Press the↑ and ↓ keys to scroll through this sub menu until Output 2 is displayed,then press the ENTER (↵↵↵↵↵) key as for Output 1 previously described.

SETUP OUTPUTS (AVERAGING 2)

The settings for averaging the second signal output are identical to thatfor signal output 1. Press the ↑ and ↓ keys to scroll through this submenu until Averaging 2 is displayed, then press the ENTER (↵↵↵↵↵) key asfor Averaging 1 previously described.

↵↵↵↵↵

→←

↵↵↵↵↵

↵↵↵↵↵

OutputsOutput 1




↵↵↵↵↵Averaging: Offxh xm xs

↵↵↵↵↵Averaging: Offxh xm xs


110

Setup Alarms (Alarms)

Two alarm facilities are available to the user, each may be programmed to trip at specified levels witha 0 to 30 seconds delay for Optical Density, Opacity or Dust as illustrated below.

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵ ↵↵↵↵↵ ↵↵↵↵↵

↵↵↵↵↵ ↵↵↵↵↵ ↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

SETUP

Outputs*↑↓

Alarms↑↓


Service*

Alarm 1↑↓

Alarm 2

AL1 Type: O.D. ↑↓ AL1 Trip: 0.00 ↑↓ Delay: 5s

AL1 type: O.D. AL1 trip: 0.00 Delay: 5s

AL2 Type: O.D. ↑↓ AL2 Trip: 0.00 ↑↓ Delay: 5s

AL2 type: O.D. AL2 trip: 0.00 Delay: 5s


111

SETUP ALARMS (ALARMS)

On selecting Alarms press the ENTER' (↵↵↵↵↵) key and Alarm 1 isdisplayed. Press the ↑ or ↓ keys to scroll through the two alarm facilities.

SETUP ALARMS (ALARM 1)

From the Alarm 1 display press the ENTER' (↵↵↵↵↵) key to access 'AL1type: O.D.'. It is now possible to scroll through three options type, tripand delay by pressing the ↑ and ↓ keys.

Alarm 1 Type (AL1 type)

On selection of AL1 type: O.D. press the ENTER' (↵↵↵↵↵) key (notice theunderlined character). The alarm type may now be selected by pressingthe ← and →. Alarm type options are Optical Density, Opacity and Dust.Once a selection has been made press the ENTER' (↵↵↵↵↵) key to continue(notice no underlined characters) or EXIT key to return to the Alarm 1display.

Alarm 1 Trip (AL1 trip)

Select AL1 trip: 0.00 by pressing the ↑ and ↓ keys from the Alarm typedisplay (notice no underlined characters). Now press the ENTER' (↵↵↵↵↵)key (notice the underlined character). The alarm trip may now be set toa value between 0 and 1000 by pressing the ← and → keys. Once setpress the ENTER' (↵↵↵↵↵) key to continue (notice no underlined characters)or EXIT key to return to the Alarm 1 display.

Alarm 1 Delay (Delay)

Select Delay: 5s by pressing the ↑ and ↓ keys from the Alarm tripdisplay (notice no underlined characters). Now press the ENTER' (↵↵↵↵↵)key (notice the underlined character). The alarm delay may now be setbetween 0 and 30 seconds by pressing the ← and → keys. Once setpress the EXIT key to return to the Alarm 1 display.

SETUP ALARMS (ALARM 2)

From the Alarm menu press the ENTER' (↵↵↵↵↵) key to access 'Alarm 2'. Itis now possible to scroll through three options type, trip and delay bypressing the ↑ and ↓ keys. Setting these values is identical to theprocedure for alarm 1 above.

↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

→←

↵↵↵↵↵

↵↵↵↵↵

↑↓

↵↵↵↵↵

SETUPAlarms

AlarmsAlarm1

AlarmsAL1 type: O.D.


AlarmsAL1 trip: 0.00

AlarmsAL1 trip: 0.00

AlarmsDelay: 5s

AlarmsDelay: 5s



112

SETUP MISCELLANEOUS (MISCELLANEOUS)

On selection press the ENTER' (↵↵↵↵↵) key. The miscellaneous menu gives access to a number ofadditional functions:

Align Dust Gain Show -veDisplay Dust OffsetO/P1 range OP 0 limitO/P2 range Station number

Access to these functions is gained as illustrated below. Return to the Miscellaneous display bypressing the EXIT key when no underlined characters are displayed.

↵↵↵↵↵

↵↵↵↵↵

SETUP

Outputs*↑↓

Alarms*↑↓

Miscellaneous↑↓

Service*

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵

↵↵↵↵↵ Station No.: x

Dust Gain: x

Dust Offset: x

OP0 Limit: x

Link: Not fitted

Signal: xxx.x

Opac. Display: %

O/P1 range: 4-20

O/P2 range: 4-20

Align↑↓

Opac. Display: %↑↓

O/P1 range: 4-20↑↓

O/P2 range: 4-20↑↓

Dust Gain: x↑↓

Dust Offset: x↑↓

OP0 Limit: x↑↓

Station No.: x↑↓

Link Not fitted↑↓

Show -ve: No

Link: Not fitted

↵↵↵↵↵


113

Alignment of Instrument (Align)

On selection press the ENTER' (↵↵↵↵↵) key to display the alignment value.Align the instrument along its optical axis (see Using The Instrument forthe First Time section) to display the maximum value. The alignmentvalue is very useful when bright sunlight makes the alignment target maybe visible. Press the ENTER' (↵↵↵↵↵) key to return to the Align display, it isnow possible to scroll through the Miscellaneous sub-menu by pressingthe ↑ ↓ keys.

Display Units (Display)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlinedcharacter). The opacity units may be selected between a percentage ora numerical value. Press the ← or → key to select the required unitsthen press the ENTER' (↵↵↵↵↵) key to set the option (notice no underlinedcharacter). It is now possible to scroll through the Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Signal Output Range (O/P 1 range)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlinedcharacter). Signal outputs may be set to one of three options 4-20, 2-20and 0-20 mA. Press the ↑ or ↓ key to select the required units thenpress the ENTER' (↵↵↵↵↵) key to set the option (notice no underlinedcharacter). It is now possible to scroll through the Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Signal Output Range (O/P 2 range)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlinedcharacter). Signal outputs may be set to one of three options 4-20, 2-20and 0-20 mA. Press the ↑ or ↓ key to select the required units thenpress the ENTER' (↵↵↵↵↵) key to set the option (notice no underlinedcharacter). It is now possible to scroll through the Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Dust Gain

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlinedcharacter). The Dust Gain is automatically set from a single isokineticsample or input manually with the figure obtained from a graph ofmultiple isokinetic samples. (See calculating the Dust Gain). Press the ↑or ↓ key to select the required value then press the ENTER' (↵↵↵↵↵) key toset the option (notice no underlined character). It is now possible toscroll through the Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Opac. Display: %

IO/P1 range: 4-20

IO/P2 range: 4-20

Dust Gain: x

Signal: xxx.x


114

Dust Offset

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlined character).The Dust Offset value sets a base line offsets in dust calibration) It isrecommended that this value is set to zero. Press the ↑ or ↓ key toselect the required value then press the ENTER' (↵↵↵↵↵) key to set theoption (notice no underlined character). It is now possible to scroll throughthe Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Output Zero Limit (OP0 Limit)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlined character).The Output Zero Limit value sets the minimum opacity value to bedisplayed (default setting of 0.04 or 4%). This complies with EPAlegislation (USA). See Error Message No 4 in Fault Finding section of theReference manual. Press the ↑ or ↓ key to select the required valuethen press the ENTER' (↵↵↵↵↵) key to set the option (notice no underlinedcharacter). It is now possible to scroll through the Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Station Number (Station No.)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlined character).The Station Number indicates the location of the instrument to the usercontrol system via the MODBUS communication protocol. Press the ↑ or↓ key to select the required value then press the ENTER' (↵↵↵↵↵) key to setthe option (notice no underlined character). It is now possible to scrollthrough the Miscellaneous sub-menu by pressing the ↑ ↓ keys.

Link (Not fitted)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlined character).The User interface requires indication no link has been fitted. Press the↑ or ↓ key to select the required value then press the ENTER' (↵↵↵↵↵) key toset the option (notice no underlined character). It is now possible toscroll through the Miscellaneous sub-menu by pressing the ↑ ↓ keys.Do not change this value without authorisation from Land Instruments.

Show negative values (show -ve)

On selection press the ENTER' (↵↵↵↵↵) key (notice the underlined character).Negative opacity values may be shown for diagnostic purposes and arerequired by certain regulatory agencies. Press the ↑ or ↓ key to selectthe required value then press the ENTER' (↵↵↵↵↵) key to set the option(notice no underlined character). It is now possible to scroll through theMiscellaneous sub-menu by pressing the ↑ ↓ keys.

Dust Offset: x

OP0 Limit: x

Station No.: x

Link: Not fitted

Show -ve: No


115

SETUP SERVICE (SERVICE)

This menu only permits access with an entry code and is reserved for the use of LAND servicepersonnel. Press the ↑ or ↓ keys to scroll through the Setup menu or press the EXIT key to return tothe menu spine.

↵↵↵↵↵

↵↵↵↵↵

SETUP

Outputs*↑↓

Alarms*↑↓


Service Entry Code: xx


116

C4-5 Display Screens

DISPLAY (DISPLAY)

On selection of Display on the menu spine press the ENTER' (↵↵↵↵↵) key. Two Display menus Top Lineand Bottom Line can be scrolled through by pressing the ↑ or ↓ keys. The display is customised byselecting the required display (see below) for both the top line and the bottom line of the display. Toreturn to the Display menu and set the selection made press the EXIT key.

Setting Top Line Display

On selection of Top Line press the ENTER' (↵↵↵↵↵) key. Press the ← or → keys to scroll through theoptions available and then press the ENTER' (↵↵↵↵↵) key again to set the option selected. The selectionwill appear on the top line of the display. To return to the Top Line sub-menu press the EXIT key.

Options available are as follows:

Opacity (displays opacity value)Optical Density (displays optical value)Dust Density (displays dust density value)Chan. 1 Average (displays average value of channel one)Chan. 2 Average (displays average value of channel two)Status (displays system status faults)Loop O/P 1 (displays current loop output 1 reading in mA)Loop O/P 2 (displays current loop output 2 reading in mA)Last Zero (displays last zero calibration value)Last Span (displays last span calibration value)Cal. Drift (displays drift between calibrations - range 0.1 to 1.0)Version (displays software version number)Blank (displays a blank line)

See next page for setting bottom line

↵↵↵↵↵↵↵↵↵↵

↵↵↵↵↵

DISPLAY

Top line↑↓

Bottom line

Optical Density*

Optical Density*


117

Setting Bottom Line Display

On selection of Bottom Line press the ENTER' (↵↵↵↵↵) key. Press the ← or → keys to scroll through theoptions available and then press the ENTER' (↵↵↵↵↵) key again to set the option selected. The display willnot change until the maintenance switch has been returned to the RUN (vertical) position. To return tothe Bottom Line sub-menu press the EXIT key.

Options available are as follows:

Opacity (displays opacity value)Optical Density (displays optical value)Dust Density (displays dust density value)Chan. 1 Average (displays average value of channel one)Chan. 2 Average (displays average value of channel two)Status (displays system status faults)Loop O/P 1 (displays current loop output 1 reading in mA)Loop O/P 2 (displays current loop output 2 reading in mA)Last Zero (displays last zero calibration value)Last Span (displays last span calibration value)Cal. Drift (displays drift between calibrations - range 0.1 to 1.0)Version (displays software version number)Blank (displays a blank line)


118

↵↵↵↵↵

PARAMETERS

SO*

C4-6 Parameter Screens

PARAMETERS

This menu contains the Model 4500 MkII+ internal parameters and is used asa general software dump with updated readings. It is not normally intendedfor customer use, but may be useful for diagnosing particular problems.

On selection of Parameters on the menu spine press the ENTER' (↵↵↵↵↵)key. Press the ↑ or ↓ keys to scroll through the parameters available forviewing, as detailed below.

So ...................... Signal detector offsetSf ....................... Signal detector flood valueSm ..................... Signal detector measurementRo...................... Reference detector offsetRf....................... Reference detector flood valueRm..................... Reference detector measurementC........................ Dust concentrationX ........................ Calibration constantB ........................ Balance correctionG ....................... Gain correction factorQ ....................... Uncorrected transmission factorDust Gain .......... Constant relating Optical Density to Dust Density.Dust Offset ........ Optical Density v Dust Density zero offset (usually zero)Zero Damper ..... Low pass digital filter applied to zero readingFlood Damper ... Low pass digital filter applied to flood LEDCal Damper ....... Low pass digital filter applied to calibrationOP 1 Damper .... Low pass digital filter applied to output 1OP 2 Damper .... Low pass digital filter applied to output 2PLCF ................. Path Length Correction FactorOPLR ................ Optical Path Length Ratio (0.5 x PLCF)Last Cal. ............ Data stored from the latest calibrationZero Comp. ....... Opacity compensation due to dust build on the lensIsokinetic O.D. ... Optical Density Calculated IsometricallyVersion x.xx ....... Identification of software version used


119

C5 System Specification

C5-1 4500 MkII+ Dust and Opacity Monitor

Measuring

Technique: Double pass/path transmissometry

Operating Wavelength: 520 ± 20 nm

Light Source: High Intensity LED

Range: Opacity 0 20 % to 0 100 %Optical Density 0 0.2 to 0 3.0Dust Density 0-100 to 0 to 4000 mg/m3

User Selectable

Linearity: < 2 % of range

Resolution: 0.1 % Opacity; 0.001 Optical Density; 0.1 mg/m3 Dust

Drift: < 1 % of range per month

Angle of Projection: < 2 o

Angle of View: < 2 o

Response Time: 1 second to 90 % of final value

Averaging: Selectable from instantaneous to 59 minutes

Pathlength: 0.7 to 10 m (2 to 33 ft) or optionally up to 20 m (66 ft)

Calibration: Automatic zero and upscale calibration(Selectable interval 1 to 24 hours in 1 hour steps)

Zero Correction: Automatic correction for zero drift

Control Panel

Display: 2 x 16 character reflective backlit LCD with adjustable contrast control

Keypad: 7 keys for data input

Indicators: System OK, Alarm 1, Alarm 2, Zero calibration, Span calibration

Weight Transceiver 15.2 kg (33 lb) with fail-safe shutters 19.2 kg (42 lb)Retro-reflector 8 kg (17.6 lb) with fail-safe shutters 11.6 kg (25.5 lb)


120

Environmental

Operating temperature: -20 to 55 oC (-4 to 131 oF )(-40 oC / -40 oF with optional heater)

Maximum Flue Gas temperature: 600 oC / 1112 oF

Maximum Flange Temp: 200 oC / 400 oF

Environmental rating: IP66 / NEMA4X

Compliance

Measurement standards: Meets or exceeds US EPA requirements for 40CFR60Sections 13, 17 and App. B PS1Meets or exceeds US EPA requirements for proposed Method 203Meets or exceeds ASTM Standard D6216 - 98 and D6216-03TUV approved to the requirements of 13th BImSchV and TA Luft

Safety: Conforms to EN-61010-2

EMC: Conforms to E-50 081 & EN-50 082

Outputs

Modbus Interface: RS232 or RS485. Opacity, Dust, Optical Density, Status,Averaging and Range information available

Analogue Outputs: Two isolated 4-20mA current outputs.Independently configurable as Opacity, Dust Optical Density,Calibration Drift or PLCF

Relay Outputs: System OK, Span calibration, Zero calibration, Alarm 1,Alarm 2, Maintenance

Continuous product development may make it necessary to change these details without notice.


121

Termination Box

Modbus Interface: RS232 or RS485 Multi-dropOpacity, Dust, Optical Density, Status, Averagingand Range Information availableCalibration sequence trigger

Analogue Outputs : Two 4-20mA current loops, fully isolated 50 V d.c.Independently configurable as: Opacity, Dust,Optical Density or Calibration Drift

Relay Outputs: System OK, Span Calibration, Zero Calibration,Alarm 1, Alarm 2, Maintenance

Relay Rating: Single Pole Changeover2A at 40 V d.c.; 2A at 230 V a.c.

Standard Termination BoxPower Supply: 90 to 260 V a.c. (universal input), 50 to 60 HzPower Consumption: 10 W

Heated Termination BoxPower Supply: 115 / 230 V a.c. (dual voltage, selectable) 50 to 60 HzPower Consumption: 60 W

Installation Category: Category II

Electromagnetic Compliance: Conforms to EN50 081-2; EN50 082-2

Operating Temperature: -20 to +55°C (-4 to +131°F)

Dimensions (H x W x D): 180 x 400 x 120 mm (7 x 16 x 5 inches)

Weight: 7.5 kg (16.5 lb)

Continuous product development may make it necessary to change these details without notice


122

C6 Testing and Checking

C6-1 Identifying Faults

The Land Model 4500 MkII+ Dust/Opacity Monitor has been designed to allow the user to troubleshoota number of possible problems and faults. If a fault condition occurs, the system OK LED on thetransmissometer will not be illuminated and the System OK relay will reset to Fault condition.Error messages may be read by pressing the Maintenance switch for 3 seconds to enter Maintenancemode, and pressing the ↵ ENTER key at the Faults menu. The display will show the number of faults,further depression of the ↵ ENTER key will display a series of fault messages.

NOTE

Non-fatal faults are reset once they have been viewed.

ERROR DESCRIPTION DIAGNOSISNUMBER

- LEDs off. No power at T-Box - check power supply.Display blank. Check fuse.

- LEDs on. Adjust contrast with Contrast key.Display blank.

- Instrument reads constant Beam blocked - check fail-safe shutters.high opacity value Check for beam blockage.

Transceiver not connected.Umbilical cable damaged.

0 Checksum error Fault in instrument memory call LANDCombustion Service Dept.

1 EEPROM Write error

2 OP0 fault Zero check failed. Repeat cal. check.

3 OPc fault Span check failed. Repeat cal. check.

4 OP0 limited Zero cal. value out of range- several causes:Dirty window - clean optics (see Maintenance).Instrument drift - check and re-calibrate.Repeat cal. check.

5 Fail in cal. Calibration failed or aborted.Repeat cal. check.Check cal. motors and micro-switches.


123

ERROR DESCRIPTION DIAGNOSISNUMBER

6 Motor jammed Zero or span cal motors failed to park.Check motors and micro-switches.

7 Measure LED fail Signal LED failed.Check connections. Replace LED.

8 Flood LED failed Flood LED failed.Check connections. Replace LED.

9 ADC over-range Analogue to Digital Converter value toohigh. Check correct aperture fitted onRetro-Reflector.Call LAND Instruments International Service Dept.

10 ADC fault Analogue to Digital Converter failed to convert.Call LAND Instruments International Service Dept.

11 Gain Drift Flood LED fault during calibration.Repeat calibration. If fault persistscall LAND Instruments International Service Dept.

12 Filter blocked Air Filter pressure switch activated.Clean/replace air filter.Check wiring between pressure switch and T-Box.

13 Blower failure Blower pressure switch activated.Check blower power supply.Check blower motor.Check wiring between pressure switch and T-Box.

14 Negative opacity Opacity value < -5%New installation: Check the path length is correct.Calibration error: Check calibration.Re-calibrate if necessary.

IMPORTANT

Whenever the Land Service Department is contacted regarding problems with aninstrument, please have available information on the instrument type and serial number.This will enable the department to respond more accurately and efficiently.


124

C6-2 Maintenance

The Land Instruments International Model 4500 MkII+ has been designed for a minimal amount ofroutine maintenance . To ensure a maximum monitor lifetime however, the following maintenanceschedule has been developed. Remember that the air purge system should always be left on, even ifthe boiler is off, to prevent any contamination of the optics. In exceptionally dirty facilities, the timeperiods below should be shortened. Frequent Op0 limited alarms or blower faults may indicate aneed to shorten the maintenance period.

ITEM MAINTENANCE PROCEDURE

Air Hoses 90 Days Examine hoses for holes or leaks.Test all hose clamps for tightness.

Pre-filter 90 Days Dust level should be below the line.(Where fitted) Remove, empty, wipe out, and replace.

Filter cover 90 Days Remove the filter from the filter housing./Rubber cup Remove the rubber cup. Empty the cup,(Where fitted) wipe out, and replace.

Filter Element 90 Days Wear eye protection, tap gently to removedust. Clean carefully with a blow gun.Examine for holes or rips. Re-fit.

Annually Replace with new filter.

Blower 90 Days Check for bearing noise. (Bearingfailure, and subsequent blower failure,can be detected early.) Check blower airflow to be sure that the blower isperforming normally. (Dirty air filters mayreduce air flow and cause undue stresson the blowers.)

Optics 90 Days Check and clean the optics as describedbelow.

Air Purge 90 Days Open the Transceiver orAdapter Retro-Reflector on its hinge and check

that there is no ash buildup inside theadapter that could block the light path.


125

During the regularly scheduled maintenance periods, any optional equipment (e.g. shutters, pressureswitches, weathercovers) should be checked for correct operation. If any potential problems arenoted, the equipment should be repaired or replaced if necessary.

Cleaning the Optical Surfaces

After prolonged use, it is likely that some contamination will occur on the optical surfaces of the Model4500 MkII+. The time taken for significant contamination to occur depends very much on the nature ofthe installation, but in a typical situation it should be sufficient to clean the optics every 90 days. Threeoptical components should be cleaned, using the lens cloth supplied by Land InstrumentsInternational.

CAUTION

Always use a lint free lens cloth to clean the optical surfaces. Ensure the cloth iskept clean. A dirty lens cloth can scratch the optical surface and cause permanentdamage to the Model 4500 MkII+. Replacement lens cloths can be purchased fromLand Instruments International. Ordinary tissues and dusters are not suitable,and can scratch the delicate optical surfaces.

To clean the Retro-Reflector, open the housing by undoing the two quick-release clamps. Loosen theaperture plate non captive screws and remove the plate over the Retro-Reflector (if fitted), carefullywipe the surface of the Retro-Reflector with the lens cloth, then replace the aperture plate. Close thehousing and fasten the two quick-release clamps.

To clean the mains lens, open the Transmissometer housing by undoing the two quick-releaseclamps. Undo the two socket headed, captive screws holding the zero-point assembly and carefullyremove it. Wipe the lens using the lens cloth, then replace the zero-point assembly. Lift the spring-loaded protective cover over the zero-point reflector and wipe the reflector. Gently replace theprotective cover. Close the housing and fasten the quick-release clamps.

CAUTION

Do not attempt to move the zero-point reflector by hand. The precision gearboxwill be irreparably damaged.

Cleaning the Termination Box

It is recommended to periodically clean the termination box to remove any build-up of dirt or dust,which may enter the box if the door is opened.


126

Changing the pathlength

The Model 4500 Premier has been configured and tested for the pathlength specified at the time ofpurchase. Changing its pathlength will alter its calibration and may invalidate any certificate of compliance.Do not change the installation pathlength without authorization from Land Instruments International.

Tools required2.5 mm hex (Allen) key5 mm hex (Allen) key - supplied

Set the correct focus

1. Open the transceiver housing by undoing the two quick-release clamps.

2. Undo the two socket headed, captive screws holding the zero-point assembly and carefullyremove it.

3. Undo the 3 M4 socket headed screws holding the lens assembly. NB These screws are NOTcaptive.

4. Carefully remove the lens assembly, taking care not to touch the lens surface.

5. Remove the o-ring from the lens and remove the focus spacers. There are 3 spacers, withthicknesses 2 mm, 4 mm and 8 mm. Select the appropriate spacers to give the correct focusdistance for the flange-to-flange pathlength shown in the table.

6. Replace the O-ring on the lens assembly.

7. Select the correct length of M3 fixing screws for the flange-to-flange pathlength shown in thetable. Carefully place the screws into the holes in the lens assembly, making sure that theypass through the holes in the focus spacers.

8. Slide the lens assembly into place.

9. Fasten all of the screws using a 2.5 mm hex (Allen) key.

10. Replace the zero-point assembly.

11. Close the housing and fasten the quick-release clamps.

Fit the correct retroreflector1. Open the retroreflector housing by undoing the two quick-release clamps.2. Undo the two M3 socket headed screws holding the retroreflector assembly and carefully

remove it. NB These screws are NOT captive3. Select the correct retroreflector for the flange-to-flange pathlength shown in the table. Fit the

retroreflector using the M3 socket-head screws.4. Close the housing and fasten the quick-release clamps.

Perform a clear stack calibration at the new pathlength see B3-3

127

Focus table

Pathlength (m) Pathlength (inches) Spacer RetroMin Max Min Max

1.000 1.028 39.4 40.5 14.5 8015231.029 1.078 40.5 42.4 14.0 8015231.079 1.132 42.5 44.5 13.5 8015231.133 1.189 44.6 46.8 13.0 8015231.190 1.250 46.8 49.2 12.5 8015231.251 1.316 49.2 51.8 12.0 8015231.317 1.387 51.8 54.6 11.5 8015231.388 1.465 54.6 57.7 11.0 8015231.466 1.549 57.7 61.0 10.5 8015231.550 1.641 61.0 64.6 10.0 8015231.642 1.742 64.6 68.6 9.5 8015231.743 1.854 68.6 73.0 9.0 8015231.855 1.977 73.0 77.8 8.5 8015241.978 2.113 77.9 83.2 8.0 8015242.114 2.266 83.2 89.2 7.5 8015242.267 2.438 89.3 96.0 7.0 8015242.439 2.633 96.0 103.7 6.5 8015242.634 2.856 103.7 112.4 6.0 8015242.857 3.112 112.5 122.5 5.5 8015243.113 3.410 122.5 134.2 5.0 8015243.411 3.760 134.3 148.0 4.5 8015243.761 4.177 148.1 164.4 4.0 8015244.178 4.679 164.5 184.2 3.5 8015244.680 5.292 184.3 208.3 3.0 8015255.293 6.050 208.4 238.2 2.5 8015256.051 6.992 238.2 275.3 2.0 8015256.993 8.139 275.3 320.4 1.5 8015268.140 10.591 320.5 417.0 1.0 801526

10.592 14.000 417.0 551.2 0.0 80152614.001 25.000 551.2 984.3 0.0 801522



128

C6-3 Replacement Parts and Consumables

Consumables

Description .......................................................................... Part Number

Lens Cloth .................................................................................. 320.804Flange Sealing Ring .................................................................. 701.981

Spares Parts

Spherical Washer ....................................................................... 702.749Spring Washer ........................................................................... 318.284M12 Locknut .............................................................................. 315.040Flange Stud ................................................................................ 702.755Microprocessor Module PCB ..................................................... 702.762Signal Processor PCB ............................................................... 702.684Measurement Detector PCB ...................................................... 702.645Reference Detector PCB ........................................................... 702.648Source LED PCB ....................................................................... 702.688Flood LED PCB.......................................................................... 702.691Air Purge Diffuser ...................................................................... 700.911Mains Lens Assembly ................................................................ 702.781Retro-Reflector Assembly (short path) ....................................... 702.829Retro-Reflector (short path)....................................................... 322.600Retro-Reflector Assembly (long path) 702.869Zero Calibration Assembly ......................................................... 702.778Zero Calibration Motor Assembly ............................................... 702.833Zero Calibration Micro Switch Assembly .................................... 702.832Upscale Calibration Assembly ................................................... 702.777Upscale Calibration Motor Assembly ......................................... 702.817Upscale Calibration Micro Switch Assembly .............................. 406.007Calibration Grating Set .............................................................. 703.803Reflector Aperture Set ............................................................... 703.793Termination Box PCB (Not including enclosure)......................... 704.226Termination Box PCB(Not incl. enclosure (Heated version) ...... 704.273Transceiver cover fitted with key panel + connectors ................ 704.271Control Panel PCB ..................................................................... 704.2282 Year Spares Kit ....................................................................... 775.006


129

Identifying Spare Parts

Spherical Washer(Part Number 702.749)

Spring Washer(Part Number 318.284)

M12 Locking Nut(Part Number 315.040)

Flange Stud(Part Number 702.755)

Lens Cloth(Part Number 320.804)

Flange Sealing Ring(Part Number 701.981)


130

Microprocessor Module PCB(Part Number 702.762)

Reference Detector PCB(Part Number 702.648)

Measurement Detector PCB(Part Number 702.645)

Flood LED PCB(Part Number 702.691)

Source LED PCB(Part Number 702.688)

Control Panel PCB(Part Number 704.228)

Signal Processor PCB(Part Number 702.684)


131

Zero calibration micro switch(Part Number 702.832)

Air Purge Diffuser(Part Number 700.911)

Main Lens Assembly(Part Number 702.781)

Retro-Reflector assembly(Part Number 702.829 short path)(Part Number 702.869 long path)

(Reflector only 322.600 short path)

Zero Calibration Assembly(Part Number 702.778)

Zero calibration motor assembly(Part Number 702.833)

Transmissometer Housing incl. keypanel and connector

(Part Number 704.271)


132

Termination Box PCB(Part Number 704.226)


133

C7 How to Get Further Assistance

Technical Assistance

Contact your local office, agent or distributor see front of manual for addresses or visit our websitewww.landinst.com.


134

C8 Configuration Record Sheet

Please complete the Configuration Record Sheet.

General Information

Instrument Serial Number

Date of Purchase

Technical Information

Pathlength

Service History

Date Action

Repair History

Date Action Part Replaced Part No.

i

Appendix Model 4500 MkII+ Dust and Opacity Monitor

Appendix A Aperture & Grating Selection Tables

AppA-1 Automatic Zero Point Reflector Aperture and Grating Selection

Aperture B ValuePlate Grating A Grating 1 Grating 2 Grating 3 Grating 4 Grating 5

B 1.69 1.30 1.00 0.74 0.52 0.34

C 1.65 1.27 0.97 0.72 0.50 0.32

D 1.61 1.23 0.94 0.69 0.48 0.30

E 1.56 1.19 0.91 0.67 0.46 0.28

F 1.52 1.16 0.88 0.64 0.43 0.26

G 1.47 1.12 0.85 0.62 0.41 0.25

H 1.43 1.09 0.82 0.59 0.39 0.23

I 1.39 1.05 0.79 0.57 0.37 0.21

J 1.35 1.02 0.76 0.54 0.35 0.20

K 1.30 0.98 0.73 0.52 0.33 0.18

Select the Aperture Plate (horizontally) and the Grating (vertically) that relate to the 'B' valueobserved after re-calibration.

AppA-2 Span Filter Grating Selection

Grating Identification Opacity Rating

R 45%

T 36%

V 28%

W 20%

X 15%

Y 10%

Z 5%

ii

Model 4500 MkII+ Dust and Opacity Monitor Appendix

Appendix B Low Temperature Termination Box

AppB-1 Termination Box Heater Unit

Brief Description

A 40W heater pad is pre-wired behind the PCB and controlled via a thermostat switch located on theunderside of the main PCB. When the temperature inside the Termination Box drops below a presetvalue on the thermostat switch, the heater pad is activated. It is deactivated when the temperaturereturns to the preset value, and so a constant operating temperature is maintained. The thermostatswitch is factory set to 0°C (32°F) and should require no further alteration.

Electrical Designation

The Termination Box is fitted with an additonal set of connectors when specified with the heaterpackage. The additonal connectors are labelled A, B, C and D, and are fitted to the left of the mainrail. The Termination Box is suitable for both 110 V and 230 V mains power. The power supplyterminals are clearly marked with a label marked 'Heater'.

NOTE: THE UNIT IS FACTORY SET TO 230 V AND NO ADJUSTMENT IS NECESSARY

Setting the Heater unit to accept 110 V mains supply

1. Ensure that the mains power supply is disconnected before proceeding.

2. Release the screws in terminals B and C.3. Remove the two short (pre-fitted) cable links from their respective connectors.4. Using the label for guidance, re-fit the cable links as indicated. One for each pair of connectors:

A and BC and D

5. No further adjustment is necessary. Re-apply mains power supply.

1.1 Thermostatically Controlled Heated Local Control Unit

A B C D

HEATER

115V

230V

!

Rev 5 Jan 2012

Gas Monitoring Products

Standard Terms of Warranty

Land Instruments International warrant all products of our own manufacture to be within specified limits of calibration,if any, when despatched from our works. Also that they are free from defects in material and workmanship fornormal use and service when used for their intended purpose within the limits of our specification. The period ofwarranty, with respect to defects in material and workmanship, will be one year from date of despatch, or readinessfor despatch should delivery be delayed by the customer who has been notified of the readiness at or after theacknowledged estimated date of despatch.

Land Instruments International guarantees to repair any defective workmanship or replace at its own option anydefective parts in any product of its manufacture, provided that the defective instrument is returned to our worksfree of charge and securely packed. Also, provided that the said goods are found to be solely defective due to faultydesign, materials or workmanship and not by improper use or accident.

Items which under their normal course of use or storage, age or deteriorate e.g. measuring cells, batteries, vacuumtubes, thermocouples, are not covered by this warranty, and will be charged for if replaced together with labourcharges for any work found not to be covered by the warranty and any transport or import charges incurred by LandInstruments International at the customers expense.

Equipment or components purchased by Land Instruments International from other manufacturers and used with orwithin Land Instruments International equipment bear only the warranty of the original manufacturer.Warranty work will only be carried out on site on receipt of an official order from the customer who will be chargedfor all travelling time plus travelling and living expenses involved to carry out the work. Should the said faulty opera-tion not be the cause of the instrument’s faulty design, materials or workmanship, but due to application conditions,Land Instruments International reserve the right to charge additionally for all labour on establishing this atthe customer’s works.

Warranty cover is subject to the correct planned maintenance being done in accordance with the published serviceschedule. Failure to follow the planned maintenance will void the warranty terms. Any warranty claim in this eventwill be at the discretion of Land Instruments International.Whilst every care is taken in the manufacture of our products, we can accept no responsibility for any consequentialloss, however caused, through the failure of any of our products to operate accurately or correctly.

All products except 4500mkIIIThe standard warranty on new instruments is a 1-year return-to-base warranty, including all electrochemical cells.. Ifrepairs are performed at site, then travelling time and expenses will be charged at standard rates. Purchased SpareParts are warranted for 1 year from date of shipment, carriage included. If a Spare Part is supplied under warranty,then this part is only warranted for the residue of the applicable warranty period. Calibration filters are not warrantedagainst any damage or change in characteristic that may occur due to mishandling.

Model 4500mkIIIThe standard warranty on new instruments is a 3-year return-to-base warranty. If repairs are performed at site, thentravelling time and expenses will be charged at standard rates. Purchased Spare Parts are warranted for 1 year fromdate of shipment, carriage included. If a Spare Part is supplied under warranty, then this part is only warranted forthe residue of the applicable warranty period. Calibration filters are not warranted against any damage or change incharacteristic that may occur due to mishandling. The 4500mkIII light source has a lifetime warranty.

Exclusions1. Warranty subject to the analysers being used in the manner for which they were designed2. Warranty subject to all recommended maintenance being performed as defined in the operatingor service manual or in the quotation3. The following consumable items are specifically excluded: All filters, Chemical filters, ChemicalDrying Agents, Batteries.

operation and maintenance manual - ametek land · model 4500 mkii + dust and opacity monitor...

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