envea STACK 710 User Manual Download

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STACK 710

USER MANUAL

Summary of Contents for STACK 710

Page 1: ...STACK 710 USER MANUAL ...

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Page 3: ...STACK 710 Particulate Measurement System USER MANUAL Publication Part Number PC 000878 MA ...

Page 4: ... revision 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 technology may warrant Trademarks All product trademarks and registered trademarks are the property of ENVEA UK Ltd All other product trademarks and registered trademarks are the property of the...

Page 5: ...e Mounting Flanges 17 3 5 Mounting Details 18 3 6 Flange Alignment Tool 18 3 7 Important information for installing the Transceiver and Retro reflector 19 3 8 Mounting the Transceiver and Retro reflector 20 3 9 Electrical Connections 21 3 10 Transceiver Connections 22 3 11 Connection to ENVEA Control Unit 23 3 12 Cable Specification 25 3 13 PC Software PC ME DUST TOOLS 26 4 GETTING STARTED _______...

Page 6: ...lt Number List 58 7 3 Maintenance 59 7 4 Cleaning the Optical Surfaces 60 7 5 Transceiver Cover 60 7 6 Configuration Record Sheet 61 ENVEA SERVICE AND SUPPORT CENTRES ___________________________ 68 List of Figures Figure 1 STACK 710 general overview 13 Figure 2 STACK 710 installation diagram 14 Figure 3 STACK 710 installation schematic 16 Figure 4 STACK 710 pathlength distance 17 Figure 5 Mounting...

Page 7: ...16 STACK 710 Transceiver 40 Figure 17 Beer Lambert s Law 48 Figure 18 Double pass system 50 Figure 19 Examples of Different Pathlength Correction Factors PLCF 52 Figure 20 STACK 710 overview 53 Figure 21 STACK 710 Transceiver 54 Figure 22 STACK 710 removing the cover 60 ...

Page 8: ...STACK 710 viii PC 000878 MA Issue 7 December 2021 ENVEA UK Ltd This page is left blank intentionally ...

Page 9: ...essure duct Protective Clothing Protective clothing must always be worn when working in the vicinity of hot vessels or ducts Storage The instrument should be stored in its packaging in a dry sheltered area Unpacking Check all packages for external signs of damage Check the contents against the packing note Return of Damaged Goods If any item has been damaged in transit this should be reported to t...

Page 10: ...sue 7 December 2021 ENVEA UK Ltd Lifting Instructions Where 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 ...

Page 11: ...e into the duct for installation or maintenance purposes If in doubt consult your local Safety Officer and or local safety procedures 1 3 Additional Information 1 3 1 Product Serial Numbers The serial number label can be found on the side of the sensor control unit enclosure The serial number on the instrument should match that on the Test Record Card which is included with the product documentati...

Page 12: ...formation available on request and for download from the ENVEA UK website see the reverse of this manual 1 4 Certification 1 4 1 Conformance and Related standards ENVEA UK Ltd hereby declares that this instrument within the limits specified in this manual conforms to the essential requirements and other provisions of the pursuant of the following 1 European Union Directives Low Voltage and EMC 2 U...

Page 13: ...ctronic and electro optic components Retro reflector Containing a corner cube reflector Air Purge System A continuous supply of purge air is essential to prevent dust and corrosive gases from affecting the optical system Single and dual electric blowers or compressed air driven devices are available to suit individual site requirements Automatic fail safe shutters can also be fitted for temporary ...

Page 14: ...he operation of the following relay outputs a SYSTEM OK b CALIBRATION c ALARMS 2 1 4 Computer Interface Operation The STACK 710 Dust opacity monitor may be connected to a computer or data acquisition system via its RS485 Modbus interface 2 2 Installation Diagram The STACK 710 Dust Opacity Monitoring System showing all components installed 1 Transceiver 2 Retro reflector 3 24V dc Power Supply 4 Dat...

Page 15: ...lecting an Installation Location The location of the mounting flanges may be affected by the type of Air Blower Unit s to be used Please refer to the Air Blower Unit manual 1 For new plants the location of the Transceiver should be planned during the design stages For existing plants the best possible location must be selected The Transceiver should be mounted so that it measures a representative ...

Page 16: ...must be level and perpendicular to the direction of gas flow Figure 3 STACK 710 installation schematic 3 3 Maintaining the pathlength during installation The installation pathlength is defined as the distance between the outer faces of the mounting flanges fitted to the stack or duct The installation pathlength must be specified at the time of order as the instrument is factory set This pathlength...

Page 17: ... inner stack plating 3 On both sides of the stack cut a hole from the liner large enough to allow welding of the mounting flange to the stack 4 Where the Transceiver will be installed cut a hole through the stack at the punched location mark 5 Where the Retro reflector will be installed make a 6 mm to 12 mm diameter pilot hole 0 25 to 0 50 6 Position the Transceiver mounting flange with the TOP la...

Page 18: ...e Transceiver mounting flange 8d to ensure alignment between the two flanges is maintained Weld the flange permanently in place 8e Make any necessary adjustments and weld the Retro reflector mounting flange permanently in place If the diameter of the stack is too large over 2m 6 5 ft to use an alignment tube ENVEA can supply an optical flange alignment tool Contact ENVEA or your local ENVEA repres...

Page 19: ...efore installation 1a Allow at least 1 m 3 3 ft for mounting and removal procedures 1b Allow a minimum of 200 mm 7 9 directly below the instrument for purge air 3 and electrical connections 4 1c Allow sufficient space to the side of each instrument to allow the hinges 6 and 7 to be opened 1d Check the Blower Unit Manual for additional installation requirements 2 The air hose fitted between the air...

Page 20: ... pairs of spring washers 5 arranged as shown these may have been removed if the flange alignment tool was used Figure 9 Mounting the Transceiver and Retro reflector 4 Place a rubber sealing band over the mounting flanges for the Transceiver and Retro reflector It cannot be fitted after the instrument is mounted on the flange 5 Remove the three M10 nuts 4 and dome washers 2 from the mounting flange...

Page 21: ...ly connections Installation should be carried out by a competent person and cables should satisfy current carrying capacity and voltage rating 3 9 1 Air Blower Unit Connections Refer to the Instruction Manual supplied with the Air Blower Unit 3 9 2 DC Supply The instrument requires a 24 V dc supply Current consumption is 0 25 A without case heaters or 2 25 A with case heaters for operation 20 C 3 ...

Page 22: ...3 Installation Instructions STACK 710 22 PC 000878 MA Issue 7 December 2021 ENVEA UK Ltd 3 10 Transceiver Connections Figure 10 Transceiver connections ...

Page 23: ...e sensor you may wire the sensor directly to the Sensor Network connector in the control unit 3 11 1 Method a Using a spur unit At control unit data cable connections are as follows from left to right Sensor Network Connector Connect the cable screen from each cable to the nearest earth stud using an eyelet tag 0V Blue Comms B RS485 D0 Orange Comms A RS485 D1 Green 24V Brown At Spur follow the wir...

Page 24: ...to sensor connector C comms 0V Black Comms B RS485 D0 Yellow Comms A RS485 D1 Green Screen Screen 3 11 2 Method b Direct sensor to control unit connection At control unit Sensor Network from left to right 0V Blue Connector A Black Connector C Comms B RS485 D0 Yellow Connector C Comms A RS485 D1 Green Connector C 24V Red Connector A Connect the cable screen from each cable to the nearest earth stud...

Page 25: ...ommended Electrical Connections Overview Nº of Cores Core Size mm2 Core Size strands dia Core Size awg Screened Supplied by 1 3 0 5 16 0 2 22 Yes ENVEA 2 8 0 25 7 0 2 24 Yes ENVEA 3 8 0 25 7 0 2 24 Yes ENVEA 4 4 0 5 to 1 5 16 0 2 to 30 0 2 22 to 16 No Customer 5 3 1 0 32 0 2 18 No Customer Figure 12 Electrical connection overview ...

Page 26: ...gher System memory 32 Mb RAM 20 Mb free hard disk space Monitor 1024 x 768 pixels high colour graphics Data communication 1 Serial port for connection to one or more instruments ProController only 2 Ethernet RJ45 via Modbus TCP 3 USB 2 0 cable standard type A to A M M Optical disc drive DVD CD PC ME DUST TOOLS software is supplied on a software CD and is also available for download from the ENVEA ...

Page 27: ...indicators The liquid crystal display normally indicates the opacity measured by the instrument Error messages and other parameters can also be displayed as explains in a later section The displayed opacity is corrected for Pathlength Correction Factor PLCF The PLCF is factory set and cannot be changed by the customer see section C1 1 Power on 2 System status 3 Calibration in progress 4 Alarm Stat...

Page 28: ...he value is correct press to store it permanently To abandon the change and revert to the previous value press The STACK 710 provides an accelerator facility for entering large numbers To increase the value hold down the arrow Initially the least significant digit is highlighted white on black The highlighted digit is incremented completing the decade in which it starts plus one more cycle through...

Page 29: ...lts 15 Calibration 46 Clear Faults 16 Settings 51 Dust Gain 1 17 Parameters 52 Dust Gain 2 18 Diagnostics 53 Dust Offset 21 Calibration Check 55 Zero Check 22 Clear Stack Calibration 56 Span Check 23 Audit 61 Confirm Clear Path 24 Gravimetric Test 62 Confirm Blocked Path 25 Confirm About Calibration 63 Test Filter Opacity 31 Calibration Check Intervals 65 Fast Response 86 Restore Previous Calibrat...

Page 30: ...e Version Number Blank A blank line So Signal Detector Offset Sf Signal Detector Flood Value Sm Signal Detector Measurement Value Ro Reference Detector Offset Rf Reference Detector Flood Value Rm Reference Detector Measurement Value C Calibration Constant slope X Calibration constant offset B Balance correction G Gain correction factor Q Uncorrected transmission factor Dust Gain Constant relating ...

Page 31: ...ay before pressing the key to confirm the value 4 5 1 Complete Installation Ensure that the installation has been completed and that the purge air blowers are running 4 5 2 Check the Pathlength Correction Factor If the STACK 710 is to be used to report Opacity the Pathlength Correction Factor PLCF must be set correctly PLCF is not relevant for Dust Density or Optical Density Extinction measurement...

Page 32: ...d or the instrument is malfunctioning 6 To move the green spot horizontally adjust the M10 nut 1 on the air purge flange and to move it vertically adjust the M10 nut 2 also on the air purge flange as illustrated in Figure 5 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 case return to the ...

Page 33: ...eturn to the Retro reflector undo the quick release clamps and swing open the rear cover It should now be possible to adjust the Transmissometer until the bright circle of sunlight visible through the Retro reflector purge unit is centred on the target Close the Retro reflector again If the green spot is visible adjust the nuts until it is central in the inner circle 4 Ensure that the 4 pairs of s...

Page 34: ...Setup Current Loop Output The STACK 710 normally provides the power supply for the current loop output It is intended to be connected to a passive input device To connect the current loop output to an active device option links inside the Transceiver must be changed Switch off the power Remove the rear cover from the Transceiver see section C 4 and locate Link 1 and Link 2 on the Main printed circ...

Page 35: ...ding to 20 mA and press Press to return to Output Range Use the and arrows to select Show Negative Values and press Use the and arrows to select Show Negative Values or No Negative Values and press Press to return to Show Negative Values If required the current loop output can be set to deliver a constant current for test purposes Use the and arrows to select Output Current and press Use the and a...

Page 36: ...ce to return to the main display The STACK 710 is now ready for use 4 12 Modbus Interface Modbus communications based on the RS485 duplex hardware standard provide direct access to the STACK 710 system data Details of the Modbus protocol are available from the Modbus website www modbus org The STACK 710 implements Functions Read Holding Register Pre set Single Register and 10 Pre set Multiple Regi...

Page 37: ...and arrows to select Parameter Number and press Use the and arrows to change the Parameter number to 1 and press Use the and arrows to change the Slave Address to the desired number in the range 1 to 247 and press Use the and arrows to change the Parameter number to 2 and press Use the and arrows to change the Slave Address to 9 00 19200 8400 or 57 00 and press Use the and arrows to change the Par...

Page 38: ...ter Data Value Description Range Scaling 127 Opacity Calculated opacity 25 100 x100 128 Optical density Calculated optical density 1 3 x1000 129 Dust density Calculated dust density 0 9999 x1 130 Dust density fractional Fractional part of the dust density Reg 503 0 99 x100 131 Average optical density Average optical density during gravimetri c test 1 3 x1000 132 Stored Average Optical Density Stor...

Page 39: ...D fail Bit 3 Flood Led fail Bit 4 ADC over range Bit 5 ADC fault Bit 12 Negative opacity Bit 13 Checksum error Bit 14 Lens contamination limit Bit 15 Failure during calibration NA 201 Average during audit 0 Off 1 On NA 202 Initiate Calibration Bit 0 Cal check Bit 1 Cal audit NA 95 Cal check interval In hours Default 24 0 1000 NA 96 Time to next cal Time to next cal in minutes 0 65535 NA Note Read ...

Page 40: ...placed in the light path The monitor reads the difference in light between the current zero point and the zero point established during the last clear stack calibration and notes this value as the amount of drift and optical dust build up The opacity value of the span filter 9 is shown on the calibration certificate which accompanies the instrument As required by ASTM D 21 07 the STACK 710 indicat...

Page 41: ...ts hinges Note Do not attempt to move the Zero Reflector 2 by hand The precision gearbox will be irreparably damaged Insert a calibrated neutral density filter into slot 1 taking care not to touch the glass Read and record the displayed opacity value Note that this value is pathlength corrected If the PLCF is set to 1 0 the displayed value should match the filter opacity If the PLCF is not 1 0 use...

Page 42: ...rrect alignment Note that unless the calibration is performed in situ the distance between the Transceiver and the Retro reflector must be adjusted until it exactly matches the distance in normal operation mm 1 4 Ensure that the pathlength is correct and that the surfaces of the main lens and Retro reflector s elements are clean and dust free Align the instrument as described in B 1 4 paragraph Pr...

Page 43: ...re displayed for use by Service Engineers The hourglass is displayed while the instrument retracts the Zero Reflector and the Upscale Filter When the hourglass disappears the Clear Stack Calibration is complete 5 4 Gravimetric Calibration Isokinetic Calibration The STACK 710 measures the opacity of dust and smoke emissions As explained in the Reference section of the manual this may be converted t...

Page 44: ...14181 A simplified procedure using Microsoft Office Excel is given below For each measurement point determine the Dust Density at the reporting conditions from the Gravimetric Test procedure and the average Optical Density indicated by the STACK 710 during the test Plot a Scatter Chart of Dust Density Y axis against Optical Density X Axis Add a Linear Trendline through the origin 0 0 and show the ...

Page 45: ...o select Dust Offset and press Use the and arrows to change the Dust Offset value as required and press Press three times to return to the main display 5 5 Setting Calibration Constants Manually If the STACK 710 is miscalibrated it is possible to recover the situation by replacing the erroneous calibration constants The Previous constants and the constants determined during Factory testing are sto...

Page 46: ...ssful Press three times to return to the main display To replace the Current Calibration constants with the Factory constants Press Unlock is displayed press Use the and arrows until the Supervisor code Default 10 is displayed and press Use the and arrows to select Calibration and press Use the and arrows to select Previous Calibration and press Use the and arrows to select Use Factory Calibration...

Page 47: ...ring later clear stack calibrations To enter the calibration constants C X and B Press Unlock is displayed press Use the and arrows until the Engineer code is displayed and press Use the and arrows to select Calibration and press Use the and arrows to select the C Constant and press Use the and arrows to change the displayed value as required and press Use the and arrows to select the X Constant a...

Page 48: ...asurement are far more sophisticated than the Ringelmann method but many of the specifications relate to the way the human eye sees smoke emissions The wavelength response of an opacity monitor must mimic that of the human eye An instrument must have a nearly photopic response The STACK 710 uses a high intensity green LED light source to achieve this 6 2 Beer Lambert s Law The mathematical relatio...

Page 49: ...becomes 1 Op e acL or Op 1 e acL Note that quantity c is the amount of dust in the optical path Optical Density or extinction is defined as OD log10 τ acL 2 303 c k x OD where k 2 303 aL By comparing a series of optical density measurements with gravimetric dust measurements taken at the same time it is possible to determine the value of k ...

Page 50: ...also be corrected in our system The Pathlength Correction Factor PLCF is only relevant for Opacity measurements It is the ratio between the diameter of the stack exit and the diameter of the stack at the point where the instrument is installed For a parallel stack the PLCF is 1 0 For a tapering stack that is narrower at the exit than the base the PLCF is less than 1 0 The Optical Pathlength Ratio ...

Page 51: ...C 000878 MA Issue 7 December 2021 51 PLCF Le Lm where Le the exit pathlength Lm the measurement pathlength OPLR PLCF 2 Ope 1 10 OD x OPLR Note The STACK 710 applies the PLCF correction only to the measured opacity Optical density is shown as the double pass value ...

Page 52: ...ht stack Measurement pathlength and exit pathlength are equal PLCF 1 00 Example 1 Straight stack monitor on the narrow duct Measurement pathlength is less than exit pathlength PLCF 1 00 Example 2 Stack narrows towards the exit Measurement pathlength is greater than exit pathlength PLCF 1 00 Example 3 Figure 19 Examples of Different Pathlength Correction Factors PLCF ...

Page 53: ...uous purge air supply is essential to prevent dust and corrosive gases from affecting the optical system Automatic fail safe shutters 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 minimal maintenance Figure 20 STACK 710 overview 6 5 2 Principle of Operation The main light source ...

Page 54: ...the concave mirror 8 which focuses it on to reference detector 7 The opacity value can be calculated from the ratio of the signals from the two detectors This is true only as long as the responsivity of the detectors and 7 and the gain of their associated electronics remains constant In practice temperature variations and ageing of the components means that this cannot be guaranteed The STACK 710 ...

Page 55: ...nstrument 6 6 System Specification 6 6 1 STACK 710 Measuring Technique Double pass path transmissometry Operating Wavelength 520 20 nm Light Source High Intensity LED Range Opacity 0 10 to 0 100 Optical Density 0 0 1 to 0 3 0 Dust Density 0 10 to 0 to 10000 mg mg User Selectable Linearity 2 of range Resolution 0 1 Opacity 0 001 Optical Density 1 mg m Dust Drift 3 of range per month Angle of Projec...

Page 56: ... 17 and App B PS1 Meets or exceeds ASTM Standard D6216 07 Safety Conforms to EN 61010 2 EMC Conforms to E 50 081 EN 50 082 Outputs Modbus Interface RS485 Opacity Optical Density Dust Density and Status information available Analogue Outputs Isolated 4 20mA current output Configurable as Opacity Optical Density Dust Density Relay Outputs System OK Calibration Alarm Power Supply DC Power 18 to 30 V ...

Page 57: ...display If the number of faults is not zero use the and arrows to select List Faults and press The first Fault Number is displayed Its meaning and the recommended action are listed in the table in section 7 2 Use the and arrows to see any other Fault Numbers If there are no other faults the number will not change Press To clear the faults use the and arrows to select Clear Faults and press The num...

Page 58: ...The Detector PCB must be optically aligned 13 Negative Opacity Check that the installation pathlength is correct Perform a Clear Stack Calibration 14 Checksum Error The microprocessor s program memory is defective Re program the Main PCB Change the Main PCB Warning All the instrument settings and calibration constants are stored on the Main PCB Re enter this data after changing the PCB 15 Lens Con...

Page 59: ...17 561 90 Days Remove the filter from the filter housing Remove the cap Empty the cap and wipe it out Wear eye protection tap gently to remove dust Clean carefully with a blowgun Examine for holes or rips Re fit Safety Filter where fitted 317 604 Annually Replace with a new filter Blower 90 Days Check for bearing noise Bearing failure and subsequent blower failure can be detected early Check blowe...

Page 60: ...rom ENVEA 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 Carefully wipe the glass surface of the Retro reflector with the lens cloth Close the housing and fasten the two quick release clamps To clean the mains lens open the Transmissometer housing by undoing the two qu...

Page 61: ... the cover ensuring that the touch panel cable is extended towards the front Stop when the cover is nearly in place and plug the touch panel connector onto the pins on the display board C Push the cover fully into place and tighten the six screws firmly and evenly Finally check that the sealing cord is evenly compressed round the case The gap between the metal parts should be 0 5 mm 7 6 Configurat...

Page 62: ...7 Maintenance STACK 710 62 PC 000878 MA Issue 7 December 2021 ENVEA UK Ltd Service History Date Action Part Replaced Part No ...

Page 63: ...STACK 710 ENVEA UK Ltd PC 000878 MA Issue 7 December 2021 63 Notes ...

Page 64: ...STACK 710 64 PC 000878 MA Issue 7 December 2021 ENVEA UK Ltd Notes ...

Page 65: ...STACK 710 ENVEA UK Ltd PC 000878 MA Issue 7 December 2021 65 Notes ...

Page 66: ...STACK 710 66 PC 000878 MA Issue 7 December 2021 ENVEA UK Ltd This page is left blank intentionally ...

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Page 68: ...a 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 Tel 44 0 1480 468 200 Fax 44 0 1480 463 400 Email service gb envea global Web www envea global ENVEA Group Headquarters 111 bvd Robespierre CS 80004 78304 POISSY CEDEX 4 France Tel 33 139 22 38 00 Fax ...

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