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envea STACK 602, User Manual

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STACK 602 

9 Maintenance 

ENVEA

 UK Ltd

 (PC-000848-MA Issue 5, December 2021)

 

vii 

5.2.4 

Setting up the Air Purges 

Air  purges  are  normally  fitted  to  the  Transmitter  and  Receiver  to  minimise 
contamination  of  the  lenses.  These  are  supplied  as  a  filter/regulator  assembly 
correctly fitted to the Transmitter and Receiver units. 

 

The air purges require a supply of dry, clean (oil-free) instrument-quality air, which 
should be set to deliver a flow rate of 30–60 l/min. Connection to the air purge is 
by a ¼” BSP fitting. 

 

NOTE

: It is recommended to adjust the air flow before

 

fitting the sensors to the stack or 

ductwork. 

5.3 

Connecting the Transmitter (Tx) 

 

Figure 12: Transmitter (Tx) PCB connections. 

 

 

Summary of Contents for STACK 602

Page 1: ...STACK 602 USER MANUAL...

Page 2: ......

Page 3: ...STACK 602 Particulate Measurement System USER MANUAL Publication Part Number PC 000848 MA...

Page 4: ...or change Revised documentation may be obtainable from ENVEA ENVEA reserves the right without notice to make changes in equipment design or performance as progress in engineering manufacturing or tech...

Page 5: ...r Options 15 2 3 System Options 16 2 4 Cabling 16 2 4 1 Data Cable Specifications 16 2 5 PC Software Suite PC ME DUST TOOLS 17 3 PRODUCT DESCRIPTION ____________________________________ 18 3 1 System...

Page 6: ...Adding Sensors 40 7 3 1 Detecting Devices Automatically Autodetect 40 7 4 Editing Basic Sensor Settings 41 7 4 1 Sensor Channels 42 7 5 Adjust Sensor Brightness and Sensitivity 42 7 5 1 Adjusting Sen...

Page 7: ..._______ 65 List of Figures Figure 1 Dimensional drawing of STACK 602 sensor 14 Figure 2 STACK 602 with 100 mm 4 mounting stubs for high temperature applications 15 Figure 3 STACK 602 DynamicOpacity Tr...

Page 8: ...ating 47 Figure 24 Maintenance Mode screen 50 Figure 25 Placing sensor in Maintenance mode 50 Figure 26 Alignment principles Transmitter 57 Figure 27 Alignment principles Receiver 58 Figure 28 Alignme...

Page 9: ...f not followed correctly NOTES are used to highlight important information that assists the user in carrying out a procedure or understanding the text In addition the following symbols are used on the...

Page 10: ...ices at all times WARNING ELECTRIC SHOCK Only connect to an earthed supply The control unit is a Class 1 construction and must be connected to a protective earth connection GND WARNING ELECTRIC SHOCK...

Page 11: ...eviation Meaning AIM Auxiliary Input Module AOM Analogue Output Module ESP Electrostatic precipitator l min Litres per minute air purge flow rate OD Outer diameter PSU Repeater Power supply unit ROM R...

Page 12: ...A website see a reverse of this manual 1 6 Certification 1 6 1 Conformance and related Standards ENVEA UK Ltd hereby declares that this instrument within the limits specified in this manual conforms t...

Page 13: ...or mist at monitoring point Inspection frequency Every 6 months see page 49 2 2 Sensor Specification STACK 602 Sensor Sensor variants Standard sensor Tx Rx 0 250 C up to 482 F High temperature option...

Page 14: ...3x M20 cable glands Air purge requirements Application dependent Recommended for positive pressure stacks or high dust loadings Requires optional air purge fitting and an external supply of 30 60 l m...

Page 15: ...3 Sensor Options Purge air options Small Purge Blower ACCAIR B Y Air Filter Regulator Advanced Filter Regulator with flow control Air Filter Regulator with automatic flow control Air purge fittings fi...

Page 16: ...least 65 C 149 F to allow for an ambient temperature of up to 50 C 122 F For information on sensor cabling requirements and considerations consult TN007 Network Cable Lengths see Related Documentatio...

Page 17: ...TOOLS The minimum system specification for desktop and laptop PCs is set out in the below table For information on hardware requirements consult the PC ME DUST TOOLS user manual see Related Documenta...

Page 18: ...to its pre decessor the SC600T which achieved both TUV QAL1 and MCERTS approvals 3 1 1 Sensor DynamicOpacity Transmitter Receiver Figure 3 STACK 602 DynamicOpacity Transceiver Receiver 1 Sensor enclos...

Page 19: ...strument problems to be self detected 3 1 2 Control Unit Two types of control units are available the Standard Controller for a standard single channel system and the Ethernet capable ProController fo...

Page 20: ...rated in mg m by comparison to the standard reference method SRM of isokinetic sampling refer to ISO 9096 for specific applications such as fixed load power plants and electrostatic precipitator ESP a...

Page 21: ...ingle sensor to the Standard Controller for a standard single channel system For more information refer to the relevant control unit manual see page 11 PRO Systems Connect multiple sensors to the ProC...

Page 22: ...able 4 Support cables at appropriate intervals 5 Do NOT route cables where they may be at risk from lightning strikes for example overexposed roofs 6 Leave sufficient length so the sensor can be remov...

Page 23: ...is will reduce the air supply to the sensor heads CAUTION Ensure the enclosure lid of the purge blower is tightened fully using turn screws This ensures the filter can operate fully to keep the air cl...

Page 24: ...ng the Purge Blower 1 Referring to Figure 5 above connect the purge blower to the sensor head by connecting the supplied straight tubing section 2x 72 mm 2 8 to the air purge inlet on each of the sens...

Page 25: ...d settings HIGH MEDIUM and LOW The typical amount of purge air required for DynamicOpacity sensors is between 30 and 60 l min under normal stack conditions typically 10 mbarg to both the Transmitter a...

Page 26: ...c safety procedures CAUTION Do NOT try to rotate or adjust the sensor by twisting its enclosure as this can damage the sensor CAUTION Non metallic parts may be cleaned with a dry or lightly dampened c...

Page 27: ...with all fixings and the required hardware pre assembled in the correct orientation An optional anti fouling fitting is available for installation between the sensor and the flanged stack mounting stu...

Page 28: ...tack duct 2 Measure or calculate the position for a hole directly opposite the first and cut a second 45 mm opening 3 If required fit the stack mounting stubs as follows 3a For smaller stacks up to 2...

Page 29: ...ilter regulator assembly correctly fitted to the Transmitter and Receiver units The air purges require a supply of dry clean oil free instrument quality air which should be set to deliver a flow rate...

Page 30: ...to bottom Wire colourF 1 SCR Cable Screen 2 8Vx Brown 3 0Vx White 4 8Vx Blue 5 TxTa Black 6 ALDr Red 7 DacD Green 8 LedIm Yellow 9 Fm1 Purple 5 3 2 Transmitter Receiver Link Settings The link connect...

Page 31: ...to the control unit power during wiring Refer to Figure 13 below for the location of the terminals After installation of the sensor make the comms and power connections as described in the below secti...

Page 32: ...to bottom as follows Pin connection Wire colourH BUS IN TERMINAL K101 I 0V Black Comms B Blue Comms A Green 24V Brown Connecting spur linked Sensor Systems Route the input cable through the cable glan...

Page 33: ...by the sensor s position in the network Set the switch to U unterminated for all sensors connected in a chain daisy chain except the last sensor which must be set to T terminated For spur linked syste...

Page 34: ...default setting is ASCII 19200 Baud No Parity 1 Stop Bit ASCII mode 7 bit RTU is a faster Comms protocol but is not available for all devices Set the address DIP switch as required see the following t...

Page 35: ...s and Functionality 6 1 1 The ProController UI Figure 15 ProController User interface with controls Use the navigation and ENTER keys to select the required menu screen Five function keys are availabl...

Page 36: ...ment Purpose Description GRAPHICAL DISPLAY 320 x 240 pixels It illuminates when the power is being delivered Status Use to view processed data alarms graphs bar charts and overview screens Navigation...

Page 37: ...TOP the top level menu icon see above to save the current screen as Favourite 2 F2 The Power LED flashes GREEN to confirm the selection has been saved SAVE YES OK Press for a positive response or to C...

Page 38: ...Set a password with a locking option to prevent unauthorised access changes SENSOR SETUP SYSTEM SETUP Main Setup screen access other functions and sensor settings from this screen Date not selectable...

Page 39: ...section 7 2 2 below or details 7 2 1 Checking the Comms Mode The Comms mode is set by ENVEA prior to installation and should have been checked during the system installation 1 Open the main Setup menu...

Page 40: ...ices Automatically Autodetect In Autodetect mode the control unit scans all Modbus addresses to identify all sensors and devices in the network Select Setup Autodetect to initiate the search The menu...

Page 41: ...Figure 19 Main Setup screen Advanced settings and additional sensors are accessed through the More Settings menu To edit the basic settings for a channel choose the required channel for example Stack1...

Page 42: ...d sensitivity settings must be adjusted so an appropriate Received Light signal is being detected at the Receiver CAUTION Adjustments to the sensor sensitivity and or brightness affect the Dust calibr...

Page 43: ...ess up from the Opacity menu on exiting the Set Up screen a confirmation dialogue Reset Opacity to Zero is displayed Select Yes to set the current Received Light level to 0 clean stack Changes in opac...

Page 44: ...ibration Factor Cal Factor The Cal Factor is used to scale the raw dust reading to provide a mg m reading within the instrument Alternatively the raw dust reading can be output to your own system usin...

Page 45: ...device These can be set to run automatically and can also be forced manually for example during installation or maintenance Frequency Span checks for the CEM are implemented automatically and are per...

Page 46: ...results show a Light Normal scintillation count of 80 51 just before the test which is reduced to 0 2 0 during the test The display now alternates between showing PASS and the numerical result 1d Opa...

Page 47: ...the self test results for a sensor Figure 23 Figure 23 Dynamic Opacity sensor test results alternating 1a Light Normal displays the current level of scintillation at the Receiver This should be the sa...

Page 48: ...reases to 273 800 during the test 2 Repeat the procedure for additional sensors as required 8 4 Setting Sensor Tests and Alarms 8 4 1 Enabling disabling Self Tests 1 Open the Setup screen then select...

Page 49: ...the advice given in the instructions 9 2 Maintenance Mode Maintenance mode allows sensors to be disabled for routine maintenance There are three ways of disabling a sensor Power OFF the control unit t...

Page 50: ...ce Mode screen 1a To put all sensors into Maintenance mode select Start Maintenance All Devices 1b To re enable all sensors select Stop Maintenance All Devices 1c To place individual sensors in Mainte...

Page 51: ...se purpose is outlined in the table below Message Time after installation Action required Inspection due 6 months Remove the sensor from the stack for inspection and cleaning Service due 12 months Arr...

Page 52: ...re Ensure that the cover lid is securely refitted 9 5 Troubleshooting WARNING HAZARDOUS VOLTAGES The control unit contains lethal voltages Always switch OFF and isolate the unit from the power supply...

Page 53: ...e with the sensor If the LED is OFF check the connections to the sensor and measure the network supply voltage between the black and red cores 9 5 4 Sensor Communications Check When the control unit c...

Page 54: ...or likely cause Step 2b and instructions on how to resolve this issue If this does not resolve the problem please contact ENVEA or your local ENVEA representative Light Normal has reached a fixed satu...

Page 55: ...djustments commonly resolve the above issues 3a If you suspect a problem with the setup repeat the alignment procedure detailed in 3b Appendix A see page 57 for instructions 3c Excessive stack vibrati...

Page 56: ......

Page 57: ...the Transmitter is not pointing directly at the Receiver the light level at the Receiver will be reduced Figure 26 Alignment principles Transmitter Receiver Rx The STACK 602 Receiver consists of a len...

Page 58: ...ode 1 Power up the Receiver Check the Transmitter is ON producing a green light source then install the Receiver accurate alignment of the sensor head is not essential at this stage 2 Install the alig...

Page 59: ...the green image exactly at the centre of the target Bolts B and C provide horizontal and vertical adjustment resp 3 Securely tighten all three bolts tighten bolts B and C at the same rate 4 Replace th...

Page 60: ...clockwise until the maximum possible reading is reached Note that the reading will go up when turning the bolts clockwise however turning them too far will cause the reading to go down again This proc...

Page 61: ...ctly proportional to the dust concentration over a predefined range Calculating the Calibration Factor The basic method to calculate a new Cal Factor a sensor uses the following formula New Cal Factor...

Page 62: ...on with a single sample or to obtain sensor averages for sample runs to send to ENVEA 1 Select the Quality Assurance Self Tests menu screen and select the required Device from the list 2 Select Calibr...

Page 63: ...g Device 2 Select the required device to edit and enter the Cal Factor 3 Select Save to store the settings and return to the main menu Calculating the Calibration Factor Automatic Method Figure 31 Cal...

Page 64: ...re sensors 0 600 C Alumina Insulator PEEK Insulator Sialon Insulator Recycling and Disposal of Electrical and Electronic Equipment In many countries separate collection systems have been set up to han...

Page 65: ...ensors purge air requirements 25 E earth wire See grounding strap earthing 23 F fitting non approved parts 10 flow rate 25 fuse 49 G grounding 9 10 24 55 grounding strap 22 M mains isolation device 24...

Page 66: ...cking 21 use intended 10 limits of 10 using alignment tool 58 analogue outputs 44 Autoset function 42 calibration tool 62 control unit See alignment Modbus outputs 44 V voltage 49 52 boost 16 drop 21...

Page 67: ......

Page 68: ...local ENVEA representative for your country or region please contact us or visit our website at www envea global ENVEA UK Ltd ENVEA House Rose Crown Road Swavesey CAMBRIDGE CB24 4RB United Kingdom Te...

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