EMS 1304 Installation And Operation Manual Download Page 38 | Manualshive

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37

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.
Replace air filters
Check all air hoses and clamps for tightness and wear, correct as necessary
Check weather cover gaskets for leakage
Check all bolts for tightness
Check all electrical connections are secure
Check air blower for excessive noise
Assure that airflow switch is operating properly

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Summary of Contents for 1304

Page 1: ... T O R S E R V I C E I N C 09 15 2011 REV 16 Model 1304 Installation and Operation Manual Environmental Monitor Service Inc PO BOX 4340 Yalesville CT 06492 Phone 203 935 0102 Fax 203 634 6663 Sales emsct com Prepared by James F Cognetta ...

Page 2: ...manual are intended to aid understanding They do not guarantee operation Environmental Monitor Service Inc accepts no responsibility for actual use of this product based on these examples Due to the great variety of possible applications for this equipment the user must assess the suitability of this product for specific applications Make sure to have safety procedures in place to stop any connect...

Page 3: ...ial promotional materials or on the face hereof for which this limited warranty may be further limited Included within this category are items produced by third party manufacturers as to which Seller passes to Buyer the warranty it has been provided by the manufacturer and items which are sold at specially reduced prices with reduced warranty protection in some cases extended warranty protection m...

Page 4: ...mware 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 NO OTHER WARRANTY IS EXPRESSED OR IMPLIED SELLER EXPRESSLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A...

Page 5: ...wing sub categories and default settings 16 Changing communication settings 17 Mounting the air plenum and weather covers 17 Mounting the air plenum and weather covers 18 Transceiver and retro reflector assembly19 Air flow switch 21 Control unit 21 S Se ec ct ti io on n 3 3 2 22 2 Before start up 22 Stack exit correlation computation22 Start up service 23 Verifying instrument operation and configu...

Page 6: ... 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 52 EMS1101 Sht 1 of 3 Dual Blower sy...

Page 7: ...______________________________________________________________________ Mailing Address ___________________________________________________________________ City State Postal Code Country _______________________________________________________ Telephone Fax ___________________________________________________________________ Instrument Model ___________________________________________________________...

Page 8: ...s The number of items being returned The part number of each item The model number or a description of each item The serial number of each item if applicable A description of the problem you are experiencing if factory repair is needed or the reason you are returning the equipment e g sales return warranty return etc When you call in our Customer Service Representative will assign an RMA Return Ma...

Page 9: ... list Photographs of damaged equipment and container You may want tot keep a copy of these documents for your records also Refer to the instrument name model number serial number sales order number and your purchase order number on all claims Upon receipt of a claim we will advise you of the disposition of your equipment for repair or replacement SHIPPING DISCREPANCIES Check all containers against...

Page 10: ...dings alarm and fault indicators analog outputs and diagnostics with contact closures Optional Air Purge Weather Cover System The transceiver and reflector may be mounted in weather covers The weather covers are fairly compact to allow movement around them even on a three foot walkway or platform They protect the stack mounted components from dirt moisture stack temperatures within the specified a...

Page 11: ...both detectors and a Measurement Reference ratio is used throughout for the calculations the monitor is insensitive to variations in light intensity Since all measurements are made on a ratio basis all resulting computations are independent of the absolute intensity of the light source or contamination of the optics associated with the collection and focusing of the energy from the lamp The T 2 si...

Page 12: ...11 Span Filter out Span Filter in Zero Reflector out Zero Reflector in RD MD Span Filter Zero Reflector Main Lamp TTL Bulls eye Projection Lens Retro Reflector Aperture P Aperture V ...

Page 13: ...pacity 20 segment LED 2 1 for window dust and drift in opacity Operator Indicating LED s Run Alarm Operate Cal in progress High Opacity Set Point 0 100 of full scale High Opacity Delay Adjustable 0 300 Seconds Hi Opacity Alarm Reset Automatic Open Transistor Collector Outputs Four selectable Dry Contacts Two selectable option two additional Instantaneous Opacity and Average Outputs 4 20 mA grounde...

Page 14: ... Compensation Automatic Light Source Life 5 years Ambient Temperature Limits 4o to 131o F 20o to 55 o C Process Gas Up to 750o F 400o C standard higher available contact factory Alignment Verification Passive Built in through the lens system Mounting Flanges 3 inch IPS 150 pipe flange Ambient Light Immunity Solid state electronic light modulation ...

Page 15: ...easily accessible area with temperatures between 32o to 122o F To permit the operator to read and or change controls the unit should not be mounted higher than five feet from floor level Stack exit Locate the transceiver more than two stack diameters down from the stack exit is recommended INSTALLATION MECHANICAL Drawing notes A review of the drawings and procedures provided will help to produce a...

Page 16: ...s See drawing section 8 An alignment tool can be purchased from the factory to insure accurate alignment Accurately locate one 3 1 2 diameter hole large enough to accept the 3 pipe and the other hole approximately 1 2 diameter directly across from each other Attach the alignment tool to the flange pipe assembly and insert the pipe into the 3 1 2 hole in the stack wall Align the assembly with the 1...

Page 17: ...f 120VAC Transceiver Power 00042 0 Alarm 1 Alarm Dust Zero Shift Alarm 00075 0 Alarm 1 Alarm High Opacity Alarm 00097 0 Alarm 1 Alarm Note always 0 during cal cycle Common Fault 00098 0 Alarm 1 Alarm Common fault individual blocks Air purge Low 00043 0 Alarm 1 Alarm No Stack Power 00042 0 Alarm 1 Alarm T2 4 20mA Lost Low 00121 0 Alarm 1 Alarm Maintenance Mode 00041 0 Alarm 1 Alarm Window Dust 0007...

Page 18: ...hoose 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 Continue as above until all settings are as desired ESC EDIT ENTER EDIT EDIT REM LOC AUTO MAN DIS ACK 19999 MESSAGE PV SP OUT EDIT Keys Hinged Cover Edit Value Light Scr...

Page 19: ... both hold down latches swing open and lift up off the hinge pins Place the Transceiver and retro in a safe place 3 The air plenum is attached to the customer supplied 3 pipe flange by four 2 1 2 long 5 8 11 bolts Working from the 3 flange the correct assembly is gasket then air plenum 4 If you have weather covers remove the two 2 weather cover hood hinge pins located on the upper right and left h...

Page 20: ...positive pressure the air purge system must be used continuously during installation to prevent process gases from contaminating optical surfaces or over heating instrument electronics If the system is shut off for more than momentary interruptions the instrument may be damaged Failure to provide continuous air purge may void the warranty All wiring from the control unit to the transceiver should ...

Page 21: ...n on the power to all air purge systems and service module 2 Align the Reflector mating flange so it is plumb and parallel to the 3 150 mounting flange Use the 3 adjusting nuts on the air purge plenum flange until this is accomplished The adjusting nuts have nylon locking inserts to prevent loosing by vibration 3 Move to the Transceiver and determine monitor alignment by looking through the viewin...

Page 22: ... and verify the switch opens Replace the leads the test is complete Control unit Mount the control unit at eye level for best viewing of the display Cut out for panel mounting is shown in the drawing section Insert the control unit through the cut out hole Insert the panel mounting hardware in the slots provided in the top and bottom of the control unit from the rear Tighten the screws until the c...

Page 23: ... must be installed and wired to the service module and customers equipment as applicable 6 All wiring and mechanical installations must be complete per drawings provided in this manual All wiring must be checked and power applied to both the control unit and the stack maintenance module 7 Beam Alignment procedure has been completed STACK EXIT CORRELATION COMPUTATION 1 The stack exit correlation is...

Page 24: ...nged cover FACTORY O P L R DISPLAY 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 or hold and scroll down until the Display reads OPLR Read Only Press the ENTER key the OPLR is displayed This is a read only block and cannot change the OPLR of the system It is intended for a convenient...

Page 25: ...nd the span filter up scale value is recorded The values are entered in the Quick Menu under Zero Cal Value and Span Cal Value When the system enters a manual or auto cal check cycle the current zero and span values are checked against the stored values If either the zero or span current value exceeds the stored value by 2 opacity the fault system will energize To verify initiate a manual cal cycl...

Page 26: ... M mode is to prevent 4 20mA outputs from changing when user is modifying block ware OPERATE Red LED is on during normal operation AUTO MAN Red LED is on during calibration check mode ZERO Red LED is on when zero cal cycle is in progress out during span or normal operation SPAN Red LED is on when span cal cycle is in progress out during zero or normal operation HIGH OPACITY Red LED is on if opacit...

Page 27: ... hold the EDIT or EDIT key until the desired set point in opacity value is displayed i e 20 00 is 20 00 opacity Press the EDIT key 4 times to return to normal operation Alarm Time Delay 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 2 times until the Display reads ALARM TIM...

Page 28: ...dule 14 13 on TB1 1101 for display at the sensor location AOUT 2 average opacity zero span when in check mode is connected at Control unit terminals 13 14 No calibration is necessary however if you want to check that other devices such as recorders or DAS are responding correctly use the following procedure Recorder or other device calibration On the control unit front panel press the AUTO MAN key...

Page 29: ...ed 11 28 2007 and up Set the cal cycle adjustment for 24 1 hours this will disable the internal clock from initiating a calibration check cycle The count down is still displayed but it has no effect To start a calibration cycle in this mode use the remote calibration cycle initiate Remote calibration cycle initiate To have an external device cause the monitor to begin calibration cycle connect a N...

Page 30: ...ity Energize in conjunction with the span filter to observe the up scale span opacity calibration point OPERATE SPAN This switch controls the span filter solenoid In the operate position the span filter is not in the measuring path and is considered normal operation When the span filter solenoid is energized the span filter is placed in the measurement path and is considered a maintenance conditio...

Page 31: ...n up scale reading 15 then slowly CCW for 0 1 opacity 7 Install the EMS Micro turn 200 on line test reflector on the transceiver and screw the device to the transceiver with the mounting screw With the thumbwheel adjust the on line reflector for the same opacity as in previous step and lock it in place 8 Place the highest value filter for best results at least a 0 8 O D in the slot provided Adjust...

Page 32: ...VALUE 1 With the zero switch in zero place the span switch in span Span is not adjustable final value is a function of filter value transceiver calibration and OPLR Record the final value you will need to enter it into the SPAN CAL VALUE in the QUICK MENU 2 Return both zero and span switches to operate normal test to normal T2 Opacity to Opacity Record the zero span values in the quick menu 1 At t...

Page 33: ... plus 11 inches The additional 11 inches compensates for air plenum spacing as the air plenums are not used for the off stack zero calibration If EMS test stands are not available an alternate method is to use 3 pipe flanges with air plenums installed contact the factory for air plenum availability Set the spacing between the 3 flanges exactly the same as Flange to Flange measurement 2 Clean trans...

Page 34: ...ection will cause the monitor to lower opacity and by turning in the opposite direction closing the iris will raise the opacity 2 Loosen clamps on the transceiver and swing it open and clean the lens use alcohol with a clean lint free paper and leave no film on the lens 3 Place the Micro Turn 200 with the reflector facing toward the Transmissometer away from the stack on the two alignment pins and...

Page 35: ...1 1 5 0 5 1 Filter re calibration is available from EMS and if not regulated by EPA regulations in your State to a more frequent schedule we suggest you re calibrate at the minimum of once a year If you have filters from other manufacturers we can also calibrate them as well call for pricing Filters are tested per USA Code of Federal Regulations 40CFR60 Appx B Performance Specification 1 Section 7...

Page 36: ...you can not bring it up after you have turned the adjustment knob as far as it will go into the Micro turn housing perform the following procedure 7 Hold the Micro turn in your hand so you can see the iris and retro reflector Turn the adjustment knob so that the iris is open as far as it will go CAUTION do not force the knob at the first sign of binding STOP 8 Next loosen the course adjustment set...

Page 37: ...al Protection Agency specifications These specifications are contained in the Code of Federal Regulations 40 CFR 60 Appendix B Performance Specification 1 Attenuator Calibration The filters are scanned over the visible region from 380 to 780 nanometers in one nanometer steps and the resulting transmittances of the filter are weighted to the Source C Human Eye Response by multiplying each value by ...

Page 38: ...orrect 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 Replace air filters Check all air hoses and clamps for tightness and wear correct as necessary Check weather cover gaskets for leakage Check all bolts for tightness Check all electrical connections are secure Check air blower for excessive nois...

Page 39: ...rs etc Observe and correct the stack zero measurement whenever a clear stack condition exists Care should be exercised to ensure that both transmittance and opacity measurements are at their prescribed values Verify that instrument operating manuals are available and that maintenance logs are properly maintained and reviewed Every 3 5 Years EMS recommends periodical depending on the severity of th...

Page 40: ...ve cleaners as they will scratch the housing and front panel Interior Dust in the interior of the control unit should be removed before it builds up enough to cause arcing and short circuits during periods of high humidity Dust is best removed from the interior by the type of canned air used for computer cleaning Dirt clinging to the surfaces can be removed with a soft paintbrush Visual Inspection...

Page 41: ...mp out 1 Adjust lamp drive PT 2 on the power modulator 1668 until Reference voltage TP 2 on signal processor 1667 is 10 0 Volts 2 Replace main lamp assembly Control unit reads High zero span values are OK 1 Smoke 2 Alignment is out 1 Correct process 2 Adjust alignment until centered on target High dust alarm and or cal fail cal message Transceiver window and or zero mirror is dirty Clean window an...

Page 42: ...rol 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 Return all to operate or neutral positions and press ACK key to clear alarms Control unit blank Control unit fuse open Replace and check for shorts in the power supply or individual boards ...

Page 43: ...per plant 1258 Standard air purge Blower Min 5CFM 36 inches H2O Max 36CFM 2 Inches H2O 1 per 4 inst Or 1 per plant 1885 Air flow switch assembly for air purge blower 2 per inst 2122 8 Pack Air filter replacement element ID 1 5 OD 4 5 HT 5 875 Black 1 per plant 1232 Micro turn 200 on line test reflector kit for EMS 13xx transceivers with 3 Neutral Density filters in hard carrying case LEVEL 2 1 per...

Page 44: ...t 1 per plant 1234 Opacity test stands for series 13xx transceiver retro 1 per plant 1078 EMS 3 pipe Flange Alignment tool 1 per plant 1073 1304 1303 control unit to service module 10 test cable Prices For price and delivery Call 203 935 0102 ext 11 Fax 203 634 6663 or email service emsct com ...

Page 45: ...44 Section 8 DRAWINGS ...

Page 46: ...45 EMS 1001 Mounting under 6 STACK ...

Page 47: ...46 EMS 1002 Mounting over 6 stack ...

Page 48: ...47 EMS 1024 Air purge Weather cover mech Installation ...

Page 49: ...48 EMS 1078 PANEL cut out for 1304 control unit ...

Page 50: ...49 EMS 1079 1304 control unit dimensions ...

Page 51: ...50 EMS 1077 Terminal identification 1304 control unit ...

Page 52: ...51 EMS 1131 1304 with recorder system wiring ...

Page 53: ...R 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 5 0 5 10 15 20 25 30 35 40 45 50 15 30 45 60 Inch H2O CFM Blower Performance Pressure ...

Page 54: ...53 EMS1101 Sht 1 of 3 Dual Blower system wiring ...

Page 55: ...54 EMS 1101 Sht 2 of 3 Single Blower system wiring ...

Page 56: ...55 EMS 1101 Sht 3 of 3 Without Blower system wiring ...

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