E N V I R O N M E N T A L M O N I T O R S E R V I C E , I N C . 09/1 5/2011 REV-1 6 Model 1304 Installation and Operation Manual Environmental Monitor Service, Inc. • PO BOX 4340 Yalesville, CT 06492 Phone 203.935.0102 • Fax 203.634.6663 Sales@emsct.com Prepared by: James F.
Ship to: ENVIRONMENTAL MONITOR SERVICE 87 Gypsy Lane Meriden, CT. 06450 Phone 203.935.0102 ext 14 Fax 203.634.6663 E-mail: service@emsct.com Warnings and Safety Guidelines Guidelines for user safety and equipment protection This manual is intended to aid trained and competent personnel in the installation of this equipment. Only a technician or engineer trained in the local and national electrical standards should perform tasks associated with the electrical wiring of this device.
1. Limited Warranty a) Warranty. i) Except as otherwise provided herein, Seller warrants to Buyer that the Products sold to Buyer are, at the time of shipment to Buyer from Seller, free from defects in material and workmanship. ii) This warranty shall be valid for a period of twelve (12) months from the date of shipment to Buyer, unless a different period is specified herein, or in Seller’s applicable price list in which case the specified period shall apply.
e) Software and Firmware Products. The sole and exclusive warranty applicable to software and firmware products provided by Seller for use with a processor will be as follows: Seller warrants that such software and firmware will conform to Seller's program manuals current at the time of shipment to Buyer when properly installed on that processor, provided however that Seller does not warrant that the operation of the processor or software or firmware will be uninterrupted or error-free.
Mounting the air plenum and weather covers 18 Transceiver and retro reflector assembly19 Air flow switch 21 Control unit 21 Section 3 22 Before start up 22 Stack exit correlation computation22 Start up service 23 Verifying instrument operation and configuration 23 EDIT Keys 23 Factory O.P.L.R.
Filter correction 33 Course adjustments 35 Micro-turn parts list 35 Filter certification 36 Section 7 37 Preventive/corrective maintenance37 Preventive/corrective maintenance schedule 37 Trouble Shooting 40 Trouble shooting -continued 41 Spare parts 42 Section 8 44 Drawings 44 EMS 1001 - Mounting under 6‘ STACK 45 EMS 1002 - Mounting over 6’ stack 46 EMS 1024 - Air purge/Weather cover mech Installation 47 EMS 1078 - PANEL cut out for 1304 control unit 48 EMS 1079 -1304 control unit dimensions 49 EMS 1077 -
WARRANTEE REGISTRATION Read this manual before attempting installation! Information contained in this manual is subject to change without notice and does not represent a commitment on the part of Environmental Monitor Service, Inc. Environmental Monitor Service, Inc. reserves the right to make changes in the construction, design, specifications, and/or procedures that may not be reflected in this manual.
Customer service We strive to provide efficient and expedient service when an instrument or component is returned for repair. Your assistance can help us to better provide the service you need. To assure that we process your factory repairs and returned goods efficiently and expeditiously, we need your help. Before you ship any equipment to our factory please call our Service Response Center at 1-800-864-2814.
CLAIMS FOR DAMAGED SHIPMENTS Inspect all instruments thoroughly on receipt. Check material in the container (s) against the enclosed packing list. If the contents are damaged and/or the instrument fails to operate properly, notify the carrier and Environmental Monitor Service immediately.
Section 1 SYSTEM DESCRIPTION The Model 1304 Opacity Monitor provides continuous, low maintenance, precision measurement of opacity and optical density in industrial applications. It is a cost-effective instrument that serves as an aid in operating pollution and/or process control equipment.
PRINCIPLE OF OPERATION Normal mode of operation The Dual beam measurement system has a stack mounted Transmissometer sensor system consists of an optical transceiver mounted on one side of the stack and a retro reflector mounted on the other. To avoid errors due to ambient light, the lamp (See Drawing) is electronically modulated and projects a collimated beam of light, which is split into a reference beam, and a measurement beam by an optical Beam splitter.
TTL Bulls-eye Projection Lens Retro Reflector Aperture P Span Filter Main Lamp RD MD Aperture V Span Filter out: Span Filter in: Zero Reflector out: Zero Reflector in: 11 Zero Reflector
04 OPACITY SPECIFICATIONS Design and performance: Meets or Exceeds PS-1 Revised and ASTM D6216-03 Peak and Mean Spectral Response Photopic; 515 to 585 nm, less than 10% of peak response outside 400 to 700 nm Relative spectral response <10% Angle of View < 4.0 o from optical axis Angle of Projection < 4.0 o from optical axis Calibration Error/accuracy +/- 1% of full scale Response time < 10 second Zero Drift < 0.5% Calibration Drift < 0.
Enclosure NEMA 4 watertight enclosure Path Length 2 to 15 feet, 0.6 to 4.6 meters.
Section 2 INSTALLATION CONSIDERATIONS Choose an installation site The primary considerations for choosing a site for the Model 1304 are accessibility, ambient environmental conditions, and locating the unit to obtain a representative sample of the process. Review the excerpt from the Federal Register in appendix for suggestions before selecting an installation site. The following general guidelines should also be considered.
Alignment of stack flanges Stack flange alignment is shown on Drawing EMS-1001 and EMS 1002, and is the first step in successful installation. The final beam alignment adjustments are described in the Beam Alignment Procedure. Installation procedure - stack flanges For an opacity monitor, the customer is required to supply and install two 3" I.P.S. flanges at eye level directly across from each other. The flange faces, mounted on pipe stubs, should be approximately 6" to 8" from the stack or insulation.
Reading Analog output Block Addresses: 0% to 100% instantaneous opacity = 40150 (integer) (xx.xx), 0% to 100% average opacity = 40151 (integer) (xx.xx), 0 to 10% Window Dust = 40073 (integer) (x.xx) Reading Discrete output Block Addresses: Relay 1- Cal in progress, duration 6 minutes (0 = cal, 1 = cal) Relay 2- High opacity alarm (0= Alarm, 1= Alarm) Note: always 0 during cal cycle. Cal. Zero Check, duration 3 minutes = 00066 (0 = cal, 1 = cal) Cal.
Changing communication settings: Press EDIT (ESC) button, Scroll down EDIT to COM MENU, press ENTER, at COM PORT press ENTER set to 1 for Modbus then press EDIT (ESC) button it will return to COM Port. (Note: controllers will automatically choose Modbus when the RS 232 port is not in use.) Press the EDIT to go to Address press ENTER and use the EDIT down or up arrow to go to the address number assigned to this controller (default is 1), press EDIT (ESC) to return to Address.
MOUNTING THE AIR PLENUM AND WEATHER COVERS WARNING! Control unit, Transceiver & Retro serial numbers must match. After the installation site has been selected and the platform requirements have been met, the mounting flanges should be installed and aligned as described on Drawings EMS - 1001 and EMS - 1002. Flanges should be installed with the mounting faces on the vertical plane. Hinge Pin 1.
Transceiver and retro reflector assembly 1. Attach the Transceiver and Retro reflector to the air plenum assembly by placing them on the hinge pins. 2. Close transceiver & retro and secure in place with the two hold down latches. 3. The air-purge blowers should be powered up at this time to prevent stack particulate from accumulating in the nipple and air-purge housing.
Beam alignment procedure Note: Alignment can not be done unless the power is applied to the stack mounted service module. The control unit does not have to be connected or powered. For alignment accuracy, the stack should be at normal temperature. Maintenance module switches should be in the normal operating positions: Zero/Operate - Operate Span/Operate - Operate Normal/Test - Normal Opacity/T2 - Opacity 1. If not already on, turn on the power to all air purge systems and service module.
Air flow switch If you have an airflow alarm when the system is powered check the airflow switch. With the blower running and the source under normal conditions disconnect the leads of the switch and place an ohmmeter across them. The switch should be closed, less than 2 ohms, if flow is enough to over come stack pressure and blower inlet is clear. Cover the air cleaner inlet and verify the switch opens. Replace the leads the test is complete.
Section 3 BEFORE START UP You must complete the following before start up is attempted. 1. Measure and record flange -to-flange distance to verify it is the same as final check out sheet. 2. If you are using a recorder, DAS, etc., DO NOT CONNECT THEM NOW. Outputs and inputs from other sources should be left off until system has been completely checked according to the following instructions. After system operation has been verified connect and test external connections. 3.
START UP SERVICE Environmental Monitor Service, Inc. is available to assist you, call our service department at (203) 935-0102 or fax (203) 634-6663 for details and to schedule start up. Verifying instrument operation and configuration Alignment procedure must be completed as outlined in Section 2. Power applied to both the control unit and the sensors for a minimum of 30 Minutes before any adjustments are attempted. Observe the front panel LED's and confirm the red Operate and the green RUN LED's are on.
ZERO/SPAN CALIBRATION CHECK The zero calibration has been set at the factory by placing the instrument on an optical bench using the flange-toflange dimensions specified by the customer and recorded in the customers final test report. This zero value is critical as it can offset smoke measurement plus or minus if not correctly set. The measurement reflector contains an aperture that is chosen during the factory calibration and is fixed.
Section 4 INSTRUMENT OPERATIONS AND ADJUSTMENTS Overview of the systems operation The Model 1304 Opacity monitor system consists of transceiver, retro reflector, service module and the control unit. The maintenance module has a digital display for reading opacity from the control unit and T2 from the transceiver. It also has connections for attaching a meter for trouble shooting or calibration when necessary. Other switches are provided for initiating zero and span modes during service or maintenance.
Control unit manual controls ACK - Acknowledges fault alarms and displays the fault message. DIS - Changes display each time it is pressed; Opacity %, Average Opacity, dust/zero shift, hours to next cal. AUTO/MAN - initiates a maintenance cal cycle and resets calibration cycle timer clock. Alarm set point adjustments Under the flip down door, press the EDIT (ESC) button (the red Edit (ESC) LED will light). The message display will read QUICK MENU.
4-20mA outputs Reference Drawing # 1131 The Model EMS1304 comes with two 4-20mA outputs. The ranges are set during final test to the information supplied by the customers. Maximum output Loop compliance is 800 Ohms. AOUT1 (instantaneous opacity, zero/span when in check mode) is connected at Control unit terminals 11 & 12 and supplies the opacity signal to a recorder or DAS and too the service module 14 & 13 (on TB1, - 1101) for display at the sensor location.
Auto cal timer Adjustment Under the flip down door, press the EDIT (ESC) button (the red Edit (ESC) LED will light). The message display will read QUICK MENU. Press the ENTER key, then the EDIT key 3 times or scroll down until the Display reads AUTOCAL CYCL TMR. Press the ENTER key twice, the Edit Value Light will flash. Press and hold the EDIT or EDIT key until the desired set point in hours is displayed, i.e. 24.00 equals 24 hour intervals. Press the EDIT key 4 times to return to normal operation.
Service module The service module is used to pass signals to and from the transceiver and control unit, display opacity via digital meter, initiate maintenance zero and span cycles and insertion of external current meter in the transceiver to control unit 4-20mA loop. - This switch selects the display of the stack digital meter. In the Opacity mode the digital displays % Opacity from the control unit. In the T2 mode it is the signal out of the transceiver in % Transmittance 2.
Section 5 AJUSTMENTS Clear on stack zero and span calibration A clear stack condition must exist to perform this calibration. Power must have been on for no less than 30 minutes. Do not attempt these adjustments in inclement weather. After the cover is removed from the transceiver normal levels of day light in the area will not effect the calibration. To complete this procedure the following items are required: EMS Micro-turn 200 on-line test kit (p/n 1232) with a high filter of at least 0.8 O.D. 1.
3. Place the Opacity/ T2 switch on the service module in the Opacity position to observe the correlated opacity on the digital display. 4. Swing open the transceiver and initiate a zero with the zero switch on the service module to raise the zero reflector into place. Observe and record the zero value after 30 seconds. Return the mirror to normal resting position by returning the zero switch to operate position. Protective Window 5.
3. This completes the calibration. Off stack zero calibration This procedure may be used if: A clear stack condition is not possible and the zero appears to be incorrect or if the flange to flange distance on site are different than the original factory set up. 1. Remove the transceiver and retro reflector from the hinge pins, remove the service module and install the system on E.M.S. test stands and at the correct flange to flange distance plus 11 inches.
Section 6 USING THE ON LINE ZERO REFLECTOR (OPTION) The "Micro-turn" 200 on - line test and audit system P/N 1232 may be used for: Opacity audit Linearity checks and adjustments System accuracy verification Service on line or off stack The "Micro-turn" 200 on - line test and audit system P/N 1232 contains a test reflector, three neutral density filters, filter certification certificates and carrying case. The Micro-turn 200 on-line test reflector is inserted over the transceiver lens.
M2 Op1 0.5 *100 OP2 1 1 100 Where: OP1 = Standard filter Value in % M2 = OPLR for your instrument OP2 = Standard Filter value at your OPLR in % Example: Standard filter value is 23.1% what will it read at OPLR of 1.5? 1.5 23.1 0.5 1 1 100 *100 54.
Course adjustments 1. Opacity is below zero and you can not reach zero after you have turned the adjustment knob as far as it will go into the Micro-turn housing perform the following procedure: 2. Hold the Micro-turn in your hand so you can see the iris and retro reflector. Turn the fine adjustment knob so that the iris is closed as far as it will go. CAUTION: do not force the knob at the first sign of binding STOP. 3. Next loosen the course adjustment set screw. 4.
Filter certification QA/QC testing by EMS of the filters at an interval of not more than 6 months is recommended. Filter certification, replacement or additional Neutral Density Filters are available from EMS. EMS Neutral Density Filters for Micro-turn 200 are calibrated on a Perkin-Elmer Lambda Series 6 / PECSS Spectrophotometer per Federal Environmental Protection Agency specifications.
Section 7 PREVENTIVE/CORRECTIVE MAINTENANCE Preventive/corrective maintenance schedule Daily: Check Zero/Span marks are within specification (+/- 2%) Check for fault conditions Monthly or as required: Clean transceiver and retro windows Check alignment, correct if necessary Check air filters replace if necessary Quarterly: All daily and monthly checks Perform COM Audit per EPA regulation 40 CFR, 60 App. B, PS-1.
Yearly: Clear stack or off stack zero All quarterly checks Remove transceiver and retro, clean air plenum Replace any worn hoses and gaskets Check all system operations General Corrective and preventive maintenance schedules should be adjusted according to site specific conditions to ensure the maximum availability of accurate measurement data.
Control unit preventive maintenance Preventive maintenance consists of cleaning the instrument regularly and inspecting it occasionally for broken or damaged parts. Regular maintenance will improve the reliability of your instrument and prevent breakdowns. Cleaning - Accumulations of dirt and dust on components act as an insulating blanket preventing efficient heat dissipation. Dust on circuit boards and wires can cause arcing and short circuits, resulting in damage to components or even instrument failure.
Trouble Shooting Problem Possible Cause Control unit reads 100%, both bargraphs are Transceiver current loop blinking, Alarm LED is on, Fault message to the control unit is open T2 4-20mA lost/low, service module meter in T2 reads -20 or higher. Alignment is good but control unit reads high opacity or erratic in normal, zero & span mode, service module meter in opacity reads high or erratic. Remedy Operate/test switch must be in Operate.
Trouble shooting -continued Problem Possible Cause Remedy Maintenance Mode message Maintenance switch or maintenance function is on Return all to operate or neutral positions and press ACK key to clear alarms. 1- Control unit zero/span key was pressed. 2- Service module zero/operate switch in zero, span/operate switch in span 3- Service module test/operate switch in test Control unit blank Control unit fuse open 41 Replace and check for shorts in the power supply or individual boards.
SPARE PARTS Level 1 - General maintenance supplies recommended for all users. Level 2 - Back up critical printed circuit boards and parts suggested permitting rapid return to service if corrective maintenance is needed. Level 2 is recommended in addition to Level 1 for those users requiring maximum instrument availability. Level 3 - If you cannot operate your facility without a monitor in operation. Level 3 is recommended in addition to Level 1 TERMS: NET 30 Days, F.O.B. Factory with credit approval.
Qty as needed 1366 Spare Model 1304 control unit, service module, transceiver & retro 3-15 Ft. 1 per plant 1234 1 per plant 1 per plant 1078 1073 Opacity test stands for series 13xx transceiver & retro EMS 3" pipe Flange Alignment tool 1304/1303 control unit to service module 10' test cable Prices: For price and delivery Call 203.935.0102 ext 11, Fax 203.634.6663 or email service@emsct.
Section 8 DRAWINGS 44
EMS 1001 - Mounting under 6‘ STACK 45
EMS 1002 - Mounting over 6’ stack 46
EMS 1024 - Air purge/Weather cover mech Installation 47
EMS 1078 - PANEL cut out for 1304 control unit 48
EMS 1079 -1304 control unit dimensions 49
EMS 1077 - Terminal identification 1304 control unit 50
EMS 1131 -1304 with recorder system wiring 51
PURGE BLOWER ELECTRICAL AND PRESSURE INFORMATION Single Phase 110VAC 50/60Hz 220VAC 50/60Hz Start Amps 9.0 4.5 Run Amps 4.5-5.7 2.2-2.8 H.P. 0.
EMS1101 - Sht 1 of 3 Dual Blower system wiring 53
EMS 1101 - Sht 2 of 3 Single Blower system wiring 54
EMS 1101 - Sht 3 of 3 Without Blower system wiring 55