envea STACK 710 User manual
STACK 710
USER MANUAL
STACK 710
Particulate Measurement System
USER MANUAL
Publication Part Number: PC-000878-MA
Publication Part No. PC-000878-MA
Issue 7
December 2021
Original language: English
Copyright © ENVEA UK Ltd 2021
All rights reserved throughout the world. No part of this
document may be stored in a retrieval system,
transmitted, copied, or reproduced in any way, including,
but not limited to photocopy, photograph, magnetic or
other records without the prior agreement and permission
in writing of ENVEA UK Ltd.
Disclaimer
ENVEA reserves the right to revise and update this
documentation from time to time without obligation to
provide notification of such 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 their respective companies.
enveais a trademark of the ENVEA Group.
Feedback
ENVEA encourages customer feedback and welcomes any
comments or suggestions relating to the product or its
documentation.
Published by:
Technical Publications
ENVEA UK Ltd
ENVEA House
Rose & Crown Road
Swavesey,
CB24 4RB, United Kingdom
Email: technicalpublicatio[email protected]
STACK 710
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) v
Table of Contents
Table of Contents.................................................................................................. v
List of Figures ......................................................................................................vi
1. INTRODUCTION______________________________________________ 9
1.1 Purpose of this Manual .................................................................................. 9
1.2 Limits of Use............................................................................................. 11
1.3 Additional Information.................................................................................. 11
1.4 Certification .............................................................................................. 12
2. PRODUCT DESCRIPTION ______________________________________ 13
2.2 Installation Diagram .................................................................................... 14
3. INSTALLATION INSTRUCTIONS __________________________________ 15
3.1 Installation Checklist ................................................................................... 15
3.2 Selecting an Installation Location .................................................................... 15
3.3 Maintaining the pathlength during installation...................................................... 16
3.4 Installing the 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 __________________________________________ 27
4.1 User Interface ........................................................................................... 27
4.2 Function Keys ........................................................................................... 28
4.3 STACK 710 Symbols................................................................................... 29
4.4 Glossary of Terms ...................................................................................... 30
4.5 Using the Instrument for the First Time ............................................................. 31
4.6 Align the Retro-reflector ............................................................................... 32
4.7 Align the Transceiver................................................................................... 33
4.8 Setup Calibration Check Interval..................................................................... 34
4.9 Setup Current Loop Output ........................................................................... 34
4.10 Setup Alarm.............................................................................................. 36
4.11 Calibration Check....................................................................................... 36
4.12 Modbus Interface ....................................................................................... 36
STACK 710
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4.13 Modbus Registers ...................................................................................... 38
5. PERIODIC MODE OF OPERATION_________________________________ 40
5.1 Calibration Check....................................................................................... 40
5.2 Calibration Audit ........................................................................................ 41
5.3 Clear Stack Calibration ................................................................................ 42
5.4 Gravimetric Calibration (Isokinetic Calibration) .................................................... 43
5.5 Setting Calibration Constants Manually............................................................. 45
6. THEORY OF OPERATION AND APPLICATION _________________________ 48
6.1 General Outline ......................................................................................... 48
6.2 Beer-Lambert’s Law .................................................................................... 48
6.3 Pathlength Correction Factor (PLCF)................................................................ 50
6.4 Examples of Different Pathlength Correction Factors (PLCF)................................... 52
6.5 Requirements for Environmental Legislation....................................................... 53
6.6 System Specification................................................................................... 55
7. MAINTENANCE _____________________________________________ 57
7.1 Identifying Faults........................................................................................ 57
7.2 Fault 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 flange schematic.......................................................................... 17
Figure 6: Front view of Air Purge showing mounting holes. .............................................. 18
Figure 7: Installing the Transceiver and Retro-reflector (side view). .................................... 19
Figure 8: Installing the Transceiver and Retro-reflector (top view)...................................... 19
Figure 9: Mounting the Transceiver and Retro-reflector................................................... 20
Figure 10: Transceiver connections. ......................................................................... 22
Figure 11: SPUR unit connections............................................................................ 23
Figure 12: Electrical connection overview. .................................................................. 25
Figure 13: User interface. ...................................................................................... 27
Figure 14: Opening the Retro-reflector case & releasing the reflector. ................................. 32
Figure 15: Aligning the Retro-reflector. ...................................................................... 33
STACK 710
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) vii
Figure 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
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viii (PC-000878-MA Issue 7, December 2021) ENVEA UK Ltd
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STACK 710 1 Introduction
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) 9
1. Introduction
1.1 Purpose of this Manual
1 Introduction STACK 710
10 (PC-000878-MA Issue 7, December 2021) ENVEA UK Ltd
STACK 710 1 Introduction
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) 11
1.2 Limits of Use
1.2.1 Danger from Process
Particulate which is toxic or in some other way hazardous to health
Particulate contained within high-temperature gas.
1.3 Additional Information
1.3.1 Product Serial Numbers
1.3.2 List of Abbreviations
Abbreviation
Meaning
ESP
Electrostatic precipitator
PSU
Power supply unit
Rx
Receiver (sensor head)
Tx
Transmitter (sensor head)
1.3.3 Related Documentation
Reference Library
ProController User Manual (Publication Part Number (PPN): PC-000859-MA)
Standard Controller User Manual (PPN: PC-000841-MA)
Installation of Network Devices- User Manual (PPN: 492501)
TN004 Installation Notes (Publication Part Number (PPN): 491021)
1 Introduction STACK 710
12 (PC-000878-MA Issue 7, December 2021) ENVEA UK Ltd
TN054 Air Purge Guide for Opacity®Sensors (PPN: 491024)
TN007 Network Cable Lengths (PPN: 491033)
PC-ME DUST TOOLS Quick Start Guide (PPN: 494003)
1.3.4 Product Parts and Options
1.4 Certification
1.4.1 Conformance and Related standards
1. European Union Directives: Low Voltage and EMC.
2. UK Regulation 2016: Low Voltage and EMC.
STACK 710 2 Product Description
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) 13
2. Product Description
Figure 1: STACK 710- general overview.
Transceiver Containing all the major electronic 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 protection in the event of a purge air failure.
2.1.1 Power Supply
2.1.2 Analogue Output
•
•
•
•
2 Product Description STACK 710
14 (PC-000878-MA Issue 7, December 2021) ENVEA UK Ltd
2.1.3 Relay Outputs
a.
b.
c.
2.1.4 Computer Interface Operation
2.2 Installation Diagram
1. Transceiver
2. Retro-reflector
3. 24V dc Power Supply
4. Data Connections
5. Air Blower Unit with Filters
6. External power isolator with
overcurrent protection
7. Blower Power Supply
Figure 2: STACK 710- installation diagram.
IMPORTANT: An external circuit breaker incorporating over-current
protection or a power isolator and fuse must be fitted to the
blower supply.
STACK 710 3 Installation Instructions
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) 15
3. Installation Instructions
3.1 Installation Checklist
1. Select the installation location.
2. Install the mounting flanges.
3. Install the Air Blower Unit(s) for the purge air supply. Consult the Air Blower
Unit Instruction Manual for full details.
CAUTION - Risk of damage to equipment
The purge air supply must be connected and working before the
Transceiver and the Retro-reflector are installed.
4. An external circuit breaker incorporating over-current protection or a power
isolator and fuse must be fitted to the blower supply.
5. Route all signal and power cables.
6. Connect the power supply to the Air Blower Unit(s).
7. Connect the electrical power supply and signals to the instruments using the
5m (16 ft) pre-terminated cables supplied.
8. Power up the air purge system.
9. Install the Transceiver and Retro-reflector; remember to connect the purge
air supply from the Air Blower Unit(s) before mounting them on the flanges.
10. Power up the instrument and calibrate it.
3.2 Selecting an Installation Location
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 concentration of dust across the stack or duct diameter.
2. If the monitor is to be used for US regulatory compliance, the locationshould
be determined by the EPA installation specifications detailed in 40 CFR 60,
Appendix B, Specification 1, or a location approved by the appropriate
agency. In Europe, the location should the determined in accordance with
EN15259.
3. At the installation location, there should be as much negative pressure as
possible, for example, a stack updraft.
4. The mounting area must have a safe walkway: if necessary, a sufficiently
large and accessible platform should be constructed.
5. The ambient temperature at the mounting location must remain between
-20 °C and +55 °C (-4 °F and 131 °F), or down to -40 °C (-40 °F) with
optional equipment. If necessary, heating, ventilation, or a sun shield should
be used to ensure this temperature range is not exceeded.
3 Installation Instructions STACK 710
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6. If the duct walls are too thin to support the instrument's weight, additional
reinforcement will be required.
7. The mounting flanges must be positioned such that the Transceiver and
Retro-reflector face each other across the centre of the stack or duct. Since
most applications involve a vertical stack, the axis common to both flanges
must be level and perpendicular to the direction of gas flow.
Figure 3: STACK 710- installation schematic
3.3 Maintaining the pathlength during installation
STACK 710 3 Installation Instructions
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) 17
Figure 4: STACK 710- pathlength distance.
3.4 Installing the Mounting Flanges
1. Each sleeve is 128 mm (5.04) long.Adjust the sleeves to obtain the proper
measurement path.
2. Accurately mark the centre of each mounting flange on the stack and punch
a locating mark through the liner onto the 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 (0.25to 0.50)
6. Position the Transceiver
mounting flange with the
label in the 12
and tack weld the mounting
flange in place.
Figure 5 Mounting flange schematic.
3 Installation Instructions STACK 710
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7. Cut a hole around the Retro-reflector pilot hole, large enough to allow
eventual welding of the outsideof the flange stub to the stack wall. The
mounting flange plate must be parallel to the stack wall.
8. If the measuring path is short (under 2m / 6.5ft) and easily accessible the
flanges can be aligned using a straight piece of tube.
8a. Slide the tube through both flanges., ensuring that the specified flange-
to-flange measuring path is maintained to within ±1%.
8b. Tack weld the Retro-reflector mounting flange in place.
8c. Make any necessary adjustments to the 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.
3.5 Mounting Details
3.5.1 Air Purge Mounting Holes
Figure 6: Front view of Air Purge showing mounting holes.
3.6 Flange Alignment Tool
STACK 710 3 Installation Instructions
ENVEA UK Ltd (PC-000878-MA Issue 7, December 2021) 19
3.7 Important information for installing the Transceiver and
Retro-reflector
Figure 7: Installing the Transceiver and Retro-reflector (side view).
Figure 8: Installing the Transceiver and Retro-reflector (top view).
1. Check the dimensions carefully before installation.
1a. Allow at least 1 m (3.3 ft) for mounting and removal procedures
1b. Allow a minimum of 200 mm (7.) 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 blower unit (see the diagram in section
A2) and its two connections on the instrument (3) must not exceed 7m (23
ft).
3 Installation Instructions STACK 710
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3. The flange-to-flange path length (5) is factory set and must not be changed.
It is given on the back of the Transceiver.
4. Pre-terminated 5 m power and data cables are supplied with this
instrument.
3.8 Mounting the Transceiver and Retro-reflector
1. Ideally, the instrument should be installed when the process is not operating
and the stack is cold.
2. The air blower unit should be operating and connected to the Transceiver
and Retro-reflector before the instrument is mounted onto the flanges.
3. Check that each mounting stud has four 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, and locate the Transceiver onto the studs (3).
6. Replace the Nyloc nuts (4) and dome washers (2) and tighten them,
compressing the spring washers (5) until there is a gap of 11 mm ()
between the two flanges, all round. Pull the sealing band (6) into place over
the gap.
7. Install the Retro-reflector following the same procedure.
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