Bulletin J-25 Particulate Monitoring Systems DPM Particulate Monitoring Systems DPM Control Units PMS Sensors INSTALLATION & OPERATING MANUAL Dwyer Instruments, Inc. 102 Indiana Highway 212 P.O. Box 373 Michigan City, IN 46361 USA Telephone 800-872-9141 www.dwyer-inst.
Particulate Monitoring Systems Installation & Operating Manual I. Technical Support & Return Procedure Dwyer Instruments, Inc. provides industry leading technical support for all product lines. The technical support department is staffed with a team of engineering professionals.
Particulate Monitoring Systems Installation & Operating Manual II. Notifications This document contains important information necessary for proper operation of the product. It is strongly urged that all users of the product read this manual in its entirety. All instructions should be followed properly and any questions that arise should be discussed with Dwyer Instruments, Inc. Any use or distribution of this document without the express consent of Dwyer Instruments, Inc. is strictly prohibited.
Particulate Monitoring Systems Installation & Operating Manual III. Approvals and Certifications CE Conformant The Control Units and Particulate Sensors conform to the appropriate country standards and governing regulations listed below: • EN 61010/1993 “Safety requirements for electrical equipment for measurement, control and laboratory use.” • EN 55011/1991 “Limits and methods of measurement of radio interference characteristics of industrial, scientific and medical equipment”.
Particulate Monitoring Systems Installation & Operating Manual IV. Specifications Ambient Temperature Range Operating Pressure Range Operating Type CONTROL UNIT SPECIFICATION 97–132V~, 47–63Hz Fuse: 0.032A, Slo-Blo 250V, Type ‘T’ Fuse: 0.050A, Slo-Blo 250V, Type ‘T’ when Self Check Option is installed 195–264V~, 47–63Hz Fuse: 0.032A, Slo-Blo 250V, Type ‘T’ Fuse: 0.050A, Slo-Blo 250V, Type ‘T’ when Self Check Option is installed 22–26VDC Fuse: 0.250A, 250V, Type ‘T’ 6 Watts Max. picoamperes (pA) 5.
Particulate Monitoring Systems PARAMETER Type Temperature Range Maximum Length Approximate Particulate Concentration Velocity Range Particle Size Range Document No. 209-1025-D Installation & Operating Manual PARTICULATE SENSOR CABLE SPECIFICATION High Quality Coaxial Operating -40°F to +392°F (-40°C to +200°C) 300 ft. DETECTION LEVEL/RESOLUTION AND APPLICATION RANGE At least 5.0 – 5000 mg/m³ 5.0pA At least 0.002 to 2.0 gr/ft³ Standard DETAIL 0.5pA Upgrade At least 0.5 to 5000 mg/m³ At least 0.
Particulate Monitoring Systems Installation & Operating Manual V. Installation Drawings Drawing Number Sheets Description 225-1016-01 2 Particulate Monitor Installation Drawings 225-1014-06 1 Particulate Flow Sensor Installation Drawing, All Mounts 225-1036 1 High Temperature / High Pressure Particulate Flow Sensor Installation Drawing Hazardous Area Control Drawing 225-1005 Document No.
Particulate Monitoring Systems Installation & Operating Manual TABLE OF CONTENTS 1. Safety............................................................................................................................................... 2 1.1 Applicable Use.......................................................................................................................... 2 1.2 General ......................................................................................................................
Particulate Monitoring Systems Installation & Operating Manual 1. Safety 1.1 Applicable Use These particulate monitor systems are not designed for use as a functional safety device and do not carry a SIL rating. The device must not be used as part of a safety system or as an input signal to a safety system. These monitors are designed for general process and environmental monitoring. 1.2 General This apparatus is available with various agency approvals as noted in the approvals section.
Particulate Monitoring Systems 1.3 Installation & Operating Manual Hazardous Area Systems Systems approved for use in hazardous areas include nameplates indicating that they are suitable for installation in hazardous areas. The nameplate lists allowable hazardous areas and T code ratings as well as approval agency markings. Do not install any device that is not tagged as suitable for the area classification.
Particulate Monitoring Systems Installation & Operating Manual 2. Introduction A Particulate Monitoring System consists of a control unit, a particulate sensor and a sensor coaxial cable. Applications include continuous emissions monitoring, baghouse filter leak detection and process particulate flow monitoring. Types of particulate include both solid particulates (dusts, powders, granulars and pellets) and liquid particulates (mists).
Particulate Monitoring Systems Installation & Operating Manual 3. Control Unit Installation 3.1 Location The following factors should be considered when determining the control unit location: Locate at a position that is convenient for setup and operation Mount at eye level Mount to a flat surface in a vertical orientation Do not mount to surfaces with excessive heat or vibration INSTALLATION PERSONNEL • Only appropriately licensed professionals should install this product.
Particulate Monitoring Systems Installation & Operating Manual There are connections inside the control unit for the sensor coaxial cable, the power supply, relay contacts and optional 4-20mA or RS-485 outputs. Refer to the installation drawings. Conduit openings are provided in the bottom of the enclosure to route wiring into the enclosure. Never drill new conduit openings in the side or top of the enclosure as a bad conduit seal may allow water to enter the enclosure. 3.
Particulate Monitoring Systems Installation & Operating Manual 4. Particulate Sensor Installation 4.1 Location The following factors should be considered when determining the sensor location: Area Classification Flow conditions Electrical (Faraday) shielding Atmospheric shielding (in the case of ducts and stacks open to atmosphere) Access for installation and service SENSOR LOCATION • Before installing the sensor, confirm area classification requirements.
Particulate Monitoring Systems Installation & Operating Manual Extreme vibration should be avoided. _ IMPORTANT 4.2 ATMOSPHERIC AND ELECTRICAL SHIELDING OF SENSOR • It is essential for the pipe/duct to provide an electrical (Faraday) shield for the sensor. The pipe/duct or stack should be metal with a high quality earth ground. Consult the factory for non-conductive pipes/ducts such as plastic or fiberglass.
Particulate Monitoring Systems 4.3 Installation & Operating Manual Sensor Temperature Considerations The sensor may be ordered with one of three process temperature ranges: 1. -40ºF to 250ºF (-40ºC to 121ºC) 2. -40ºF to 450ºF (-40ºC to 232ºC) 3. -40ºF to 800ºF (-40ºC to 426ºC) 4. Consult Factory for Temperatures >800°F Note: For the process temperatures in the range of 233ºC - 426ºC, a high temp probe must be used. The maximum allowable ambient temperature at sensor housing is 70ºC.
Particulate Monitoring Systems Installation & Operating Manual 5. Particulate Sensor Coaxial Cable Installation Connection: Prior to making coaxial cable connections review the following routing instructions. IMPORTANT _ PARTICULATE SENSOR COAXIAL CABLE ROUTING • The sensor cable must be installed in conduit that is separate from all other wiring.
Particulate Monitoring Systems Installation & Operating Manual Sensor Test Port (Non-Hazardous Areas Only) Location: A test port should be installed in a negative pressure location. It must be located upstream of the sensor so particulate can flow very near and around the sensor. It should be located at least 3 ft (1 m) upstream of the sensor and it should be located on the same side of the duct as the sensor so particles can pass very near and around the sensor.
Particulate Monitoring Systems Installation & Operating Manual 6. Control Unit Operation 6.1 User Interface Overview The following drawing shows the user interface consisting of a four-button keypad and an LCD display. The LCD display has a scalable analog bar graph combined with a digital readout for ease in interpreting the dynamic readings, which are typical with particulate flow.
Particulate Monitoring Systems 6.2 Installation & Operating Manual Menu 1 Setup Alarm setpoints are accessed through Menu 1 setup. To enter Menu 1, press the SETUP key. Setpoints may be modified by pressing the UP and DOWN arrow keys. Values are saved by pressing the ENTER key. To discard any changes made and return to the main screen, press the SETUP/ESCAPE key. Refer to the Menu 1 setup diagram below for menu navigation and allowable setpoint ranges.
Particulate Monitoring Systems 6.3 Installation & Operating Manual Menu 2 Setup Navigation within Menu 2 is similar to that described in Menu 1. Features designated with an asterisk (*) are optional. Operation of optional features is dependant upon model and options selected at the time of order. The following setup menus are based on firmware version 2.27 or higher. Press the SETUP and ENTER keys at the same time from any main screen to enter the Menu 2 setup screen.
Particulate Monitoring Systems Document No. 210-1003-M Installation & Operating Manual Fail-safe Relay 1 No/Yes When set to “Yes”, inverts the alarm relay logic. Relay is ON when NO alarm condition exists and is OFF when there IS an alarm condition. Relay is OFF when power is removed from the control unit. Fail-safe Relay 2 No/Yes When set to “Yes”, inverts the alarm relay logic. Relay is ON when NO alarm condition exists and is OFF when there IS an alarm condition.
Particulate Monitoring Systems 6.4 Installation & Operating Manual Menu 3 Setup Navigation within Menu 3 is similar to that described in Menu’s 1 and 2. Features designated with an asterisk (*) are optional. Operation of optional features is dependant upon model and options selected at the time of order. The following setup menus are based on firmware version 2.27 or higher. Press the UP and DOWN keys at the same time from the main screen to enter the Menu 3 setup screen.
Particulate Monitoring Systems 6.5 Installation & Operating Manual Long Term Averaging The long term averaging function provides a rolling average of the real-time readings over time. Press the ENTER key to toggle between the Real-Time display and the Average display. Main Screen Units Shown Description Real-Time Display pA Displays the real-time reading. Before display, the real-time reading is processed through a low-pass input signal filter which smoothes the reading.
Particulate Monitoring Systems 6.6 Installation & Operating Manual 4-20mA Analog Output Scaling Particulate levels may be transmitted to external devices with the 4-20mA analog output. Typical applications include remote monitoring of particulate levels with a PLC, chart recorder or panel meter. The 4-20mA output is transmitted as linear or multi-decade logarithmic output. Two parameters determine the type of output signal.
Particulate Monitoring Systems Installation & Operating Manual 4-20mA Logarithmic Output To convert the 4-20mA logarithmic output back to pA, use the following formula: 1. Compute the number of output decades: Number_Of_Decades =Log [(4-20mA Output Span)/(4-20mA Minimum_Scale)] 2. Scale mA input to proper log(10) argument: Y = Number_Of_Decades * (mA – 4.00) / 16 3. Convert log(10) argument to pA: pA = 10^(Y) * (4-20mA Minimum_Scale) Example #1: See Menu #2 for details.
Particulate Monitoring Systems Installation & Operating Manual Example #2: See Menu #2 for details. Where: 4-20mA Output Minimum Scale = 0.5pA 4-20mA Output Span = 500pA Number_Of_Decades = Log (500 / 0.5) = 3 4-20mA Output 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 6.7 Y 0.00 0.19 0.38 0.56 0.75 0.94 1.13 1.31 1.50 1.69 1.88 2.06 2.25 2.44 2.63 2.81 3.00 pA 0.5 0.8 1.2 1.8 2.8 4.3 6.7 10.3 15.8 24.3 37.5 57.7 88.9 136.9 210.8 324.7 500.
Particulate Monitoring Systems IMPORTANT Installation & Operating Manual PARTICULATE READING GUIDE FOR FABRIC FILTERS • The guide below is only an approximate guide for modern, highly-efficient baghouses • With larger or older baghouses, readings can be significantly higher than the ranges shown below • Shaker and reverse air baghouses will have higher peak readings as compared to pulse jet • Readings tend to be higher when new filters are installed and a filter cake has yet to form • With smal
Particulate Monitoring Systems 6.8 Installation & Operating Manual Alarm Levels for Fabric Filter Applications For fabric filter applications it is recommended to set two alarm levels either using the internal alarms and or using the optional 4-20mA output signal that is sent back to a PLC or other recording system. One alarm should be set based on the average base line reading and another alarm should set based on the peak readings following cleaning cycles.
Particulate Monitoring Systems Installation & Operating Manual 7. Manual System Zero Check The System Zero Check is used at installation to confirm proper installation and for troubleshooting. This check is mostly for control units that are not equipped with the optional self check subsystem. SAFETY • Always disconnect power to the control unit before making any wiring changes at either the control unit or sensor as well as when making any mounting changes or replacing any component.
Particulate Monitoring Systems Installation & Operating Manual CONTROL UNIT ZERO CHECK 1. Disconnect power to the control unit. 2. Open the enclosure cover and unscrew the coaxial cable connector from the control unit. Leave the connector inside the control unit enclosure. Make sure the connector does not slip down into the conduit. 3. Close the control unit enclosure cover. 4. Re-apply power to the control unit and allow the reading to stabilize for 1-2 minutes. 5. Read the display.
Particulate Monitoring Systems Installation & Operating Manual Once the control unit and coaxial cable zero have been checked, proceed to the Sensor Zero Check. To perform the sensor zero check the process flow must be stopped or a sensor test pipe (available from Factory) or length of metal pipe will be needed (4”-6” diameter pipe or larger). The pipe should be at least 3 in (8 cm) longer than the probe itself and must be grounded.
Particulate Monitoring Systems Installation & Operating Manual 8. Automatic Self Checks An optional self check subsystem is available to automatically verify calibration and proper operation of the electronics, sensor and cable. Self checks can be performed while the system is online and monitoring particulate. No external test equipment or operator intervention is required to activate or complete the self check routines.
Particulate Monitoring Systems 8.2 Installation & Operating Manual Control Unit Zero Check The Zero Check will verify instrument zero calibration. The internal self check subsystem will automatically perform the following procedure: 1. Electronic disconnect of the particulate sensor cable 2. Allow the reading to stabilize 3. Measure the reading and compare to the allowable zero tolerance 4. Electronic re-connect of the particulate sensor cable and resume normal operation.
Particulate Monitoring Systems 8.3 Installation & Operating Manual Control Unit Span Check The Span Check will verify the instrument span calibration. The internal self check subsystem will automatically perform the following procedure: 1. Electronic disconnect of the particulate sensor cable 2. Electronic input of a calibrated pA reference signal 3. Allow the reading to stabilize 4. Measure the reading and compare to the allowable span tolerance 5.
Particulate Monitoring Systems 8.6 Installation & Operating Manual Process Running Signal A process running signal indicates to the control unit whether the main process fan is ON or OFF. Connection of a process running signal adds the following capabilities to the automatic self check subsystem: 1. Sensor cable check – reference section 8.4 for further details. 2. Automatic system zero – verifies zero of the total system electronics, cable and sensor while fully installed in the process.
Particulate Monitoring Systems Installation & Operating Manual Alarm Relay An alarm output relay can be activated if any self checks are unsuccessful. The alarm relay will remain activated until a subsequent self check is performed successfully, or power to the control unit is disconnected. Alarm relay #1 will be activated in the event of a self check failure by default. Alarm output relays may be configured to operate in normal or fail-safe modes.
Particulate Monitoring Systems Installation & Operating Manual 9. Troubleshooting The following is primarily used when troubleshooting a system without the optional automatic self checks. When troubleshooting, consider each component of the system: The control unit, the sensor coax cable and the sensor assembly. False High Signals (False Alarms) 1. When an apparent false high signal is present, first check the process to be sure the particulate level has not increased.
Particulate Monitoring Systems Installation & Operating Manual 11. Spare Parts Item Line Fuse, 115/230VAC Details 0.032A 250V Slo-Blo type ‘T’ Mfr Part No. LittleFuse 218.032 0.050A 250V Slo-Blo type ‘T’ when Self Check Option is installed LittleFuse 218.050 Line Fuse, 24VDC 0.250A 250V Slo-Blo type ‘T’ Control Unit Control Unit Family Refer to Product Label Particulate Sensor Variable Lengths & Connections Refer to Product Label Particulate Sensor Cable Coax, SMA x Ring Lugs Document No.
Particulate Monitoring Systems Installation & Operating Manual 12. Appendix Modbus®/RTU RS-485 Networking Protocol Ethernet/IP® Networking Installation & Hazardous Area Control Drawings Document No.
Particulate Monitoring Systems Installation & Operating Manual 12.1 Modbus®/RTU RS-485 Networking Protocol The RS-485 networking feature allows up to 32 control units to be connected to a multi-drop communications network. When connected to the network, any device on the network may be monitored and controlled by a remote device such as a PLC or Computer using Modbus®/RTU protocol.
Particulate Monitoring Systems Installation & Operating Manual Personal Computer Connection Connection to a personal computer is made to the RS-232 COM port with the addition of a converter module. Converter modules are available from the factory. The converter module modifies the voltage levels and wiring connections to allow different RS connections to work together. Converter modules generally require their own power source, which may be supplied with a wall-mount transformer power supply.
Particulate Monitoring Systems Installation & Operating Manual Modbus®/RTU Registers Register Description Address 0x Reference: Discrete output coils 00001 Alarm relay 1 (1=ON, 0=OFF) 00002 Alarm relay 2 (1=ON, 0=OFF) 03073 Alarm status - alarm 1 (1=ON, 0=OFF) 03074 Alarm status - alarm 2 (1=ON, 0=OFF) 03247 Zero Check Running Status (1=Running, 0=Not Running) 03248 Span Check Running Status (1=Running, 0=Not Running) 03249 Full System Zero Check Running Status (1=Running, 0=Not Running) 03251 Zero Check
Particulate Monitoring Systems Installation & Operating Manual 12.2 Ethernet/IP® Networking The Ethernet/IP® networking feature allows communication between control units and other devices on an Ethernet/IP® network. Ethernet/IP® is a common networking protocol supported by Allen-Bradley equipment and other third party vendors. Network Hardware Description Ethernet is one of the most common networking topologies in use today.
Particulate Monitoring Systems Installation & Operating Manual Network Addressing and BOOTP Behavior Communication over an Ethernet network typically requires a device to be setup with two addressing parameters, a MAC address and an IP address. The MAC address of the Ethernet/IP® module is fixed and is listed on the enclosure. The IP address is set to a factory default value of 192.168.0.254 with subnet mask 255.255.255.0 when shipped.
Particulate Monitoring Systems 6. 7. 8. Installation & Operating Manual Service Class Instance Attribute Data 0x45 0x67 0x89 0xAB 0xCD BOOTP operation within the module must be DISABLED. To DISABLE BOOTP operation the following explicit message must be sent to the module: Service Class Instance Attribute Data 0x10 0x64 0x01 0x6E 0x00 Cycle power to the module. Once power is re-applied the module will come online with the new IP address and Subnet mask.
Particulate Monitoring Systems 2:11 Thru 2:15 3 4 5 6 7 8 9 10 11 12 - 0 1 40609 40610 40611 40612 40737 40738 40739 40740 40769 40770 0 5000 0 Installation & Operating Manual Bool Not Used pA Float 5000 pA Float 0 5000 pA Float 0 5000 pA Float 0 0 600 600 Particulate process variable LO word Particulate process variable HI word Averaged particulate process variable LO word Averaged particulate process variable HI word Alarm level – Max alarm #1 LO word Alarm level – Max alarm #1 H
Particulate Monitoring Systems Installation & Operating Manual Configuration Assembly Object (Class 0x04, Instance 0x80) The configuration assembly object is not implemented. However, some Ethernet/IP® clients require one. If this is the case, use Instance ID 0x80 with a data length of 0. Document No.
Particulate Monitoring Systems Installation & Operating Manual Notes: Document No.
