GREEN INSTRUMENTS G26 User manual

G26
Ex Opacity System
Instruction Manual
Document ID number.: 103520

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Ex-Opacity G26 System
Ver.2.1 – Revision March 2022 Page 3 of 56
Content
1INTRODUCTION .............................................................................................6
1.1 ABOUT THIS MANUAL .....................................................................................................6
1.2 INQUIRIES AND FEEDBACK ..............................................................................................7
1.3 ABOUT THE SYSTEM ......................................................................................................7
1.3.1 System Components ...................................................................................8
1.3.2 Additional Components ...............................................................................8
2SPECIFICATIONS ...........................................................................................9
3SAFETY ASPECTS ....................................................................................... 11
4CONTROL AT DELIVERY ...............................................................................13
5INSTALLATION.............................................................................................14
5.1 SYSTEM OVERVIEW .....................................................................................................14
5.2 CONTROL AND MONITORING UNIT .................................................................................15
5.3EX INTERFACE CABINET WITH INTRINSIC SAFETY BARRIERS...........................................15
5.4 EX JUNCTION BOX .......................................................................................................15
5.5 TRANSCEIVER AND REFLECTOR ....................................................................................15
5.5.1Mounting Brackets .....................................................................................16
5.5.2 Choosing Installation Location...................................................................17
5.6 ELECTRICAL CONNECTIONS..........................................................................................17
5.6.1 Connections...............................................................................................17
5.6.2 Cable .........................................................................................................17
5.7 CHOOSING THE RIGHT ALARM LEVELS – OPACITY OF OIL MIST..........................................18
6TRANSCEIVER MENU STRUCTURE ................................................................19
6.1 TRANSCEIVER BUTTON FUNCTION ................................................................................19
6.2 CHOOSE TRANSCEIVER TYPE.......................................................................................20
6.3 SET LASER ALIGNING FUNCTION ..................................................................................22
6.4 SET UNIT ADDRESS .....................................................................................................23
6.5 CALIBRATION ...............................................................................................................25
6.5.1 Zero Calibration .........................................................................................25
6.5.2 Auto SPAN Calibration...............................................................................25
6.5.3 Manual Span Calibration ...........................................................................26
6.6 ENABLING SERVICE MODE ...........................................................................................27
7CONTROL AND MONITORING UNIT ................................................................29
7.1 HOME MENU ...............................................................................................................29
7.2 TRANSCEIVER MENU....................................................................................................30

Content
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7.3 ALARM LIST MENU ......................................................................................................31
7.4 TREND MENU..............................................................................................................34
7.5 TRANSCEIVER SETUP ..................................................................................................34
7.6 SYSTEM SETUP...........................................................................................................36
8COMMISSIONING ......................................................................................... 38
8.1 START OF THE SYSTEM................................................................................................ 38
8.2 CALIBRATION ..............................................................................................................38
8.3 SETTING OF ALARM LEVELS......................................................................................... 38
8.4 SETTING OF SIGNAL OUTPUTS .....................................................................................38
9MAINTENANCE ........................................................................................... 39
9.1 GENERAL ...................................................................................................................39
9.2 MAINTENANCE INSTRUCTION .......................................................................................40
10 TROUBLESHOOTING....................................................................................41
11 SPARE PARTS ............................................................................................ 43
12 APPENDIX OF EX-OPACITY TRANSCEIVER G16/G26 ..................................... 46
12.1 ABOUT THIS APPENDIX ................................................................................................46
12.1.1 Labeling.....................................................................................................46
12.2 TYPE APPROVAL STANDARDS ......................................................................................48
12.3 WARNING ...................................................................................................................48
12.4 SAFETY USE ...............................................................................................................48
12.4.1 Notes on Safe Use of the ATEX and IECEx Approved Equipment ...........48
12.5 INSTALLATION..............................................................................................................49
12.5.1 Installation Requirements .........................................................................49
12.5.2 Protective Earth ........................................................................................49
12.5.3 Installation Examples ................................................................................50
12.6 MOUNTING, COMMISSIONING, AND OPERATION .............................................................50
12.6.1 Explosive Hazardous Area........................................................................51
12.6.2 Special Conditions for a Safe Use ............................................................51
12.7 MAINTENANCE ............................................................................................................51
12.7.1 External Maintenance ...............................................................................51
12.7.2 Overhaul and Repair.................................................................................51
12.8 CLASSIFICATION..........................................................................................................51
12.8.1 Zone Classification....................................................................................52
12.8.2 Gas Grouping............................................................................................52
12.8.3 Dust Grouping ...........................................................................................52
12.8.4 Temperature Classification........................................................................ 52
12.9 ACCESSORIES ............................................................................................................53

Ex-Opacity G26 System
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12.9.1 Connection Cable ......................................................................................53
12.9.2 Transceiver Mounting Module G26 ...........................................................53
12.9.3 Reflector Module G16................................................................................53
12.9.4 Reflector Module G26................................................................................53
12.9.5 Air Module G16/G26 ..................................................................................53
12.9.6 Junction Box ..............................................................................................53
12.10 SPARE PARTS..............................................................................................................53
TABLE OF FIGURES
FIGURE 5-1: EX OPACITY G26 SYSTEM COMPONENT OVERVIEW ..............................................................................................................14
FIGURE 5-2: MOUNTING POSITION OF THE TRANSCEIVER AND THE REFLECTOR .......................................................................................... 16
FIGURE 5-3: OPACITY VERSUS PATH LENGTH FOR DIFFERENT CONCENTRATION (CALCULATED FOR OIL DROPLETS OF 10…20µM). ...................18
FIGURE 6-1: TRANSCEIVER INTERFACE ...................................................................................................................................................19
FIGURE 6-2: ILLUSTRATION OF THE STRONGEST SIGNAL →NO OBSTRUCTIONS TO THE LIGHT BEAM .............................................................. 19
FIGURE 6-3: ILLUSTRATION OF THE WEAKEST SIGNAL →OBSTRUCTIONS TO THE LIGHT BEAM ....................................................................... 20
FIGURE 6-4: SELECT CONFIGURE MENU ................................................................................................................................................. 20
FIGURE 6-5: THE CONFIG MENU WILL HAVE THE RIGHT MOST SIGNAL STRENGTH LED TURNED ON (TRANSCEIVER TYPE MENU).......................21
FIGURE 6-6: TRANSCEIVER TYPE MENU TURNED ON................................................................................................................................. 21
FIGURE 6-7: TRANSCEIVER TYPE WHERE ALARMS ARE BASED ON ABSOLUTE OPACITY .................................................................................. 21
FIGURE 6-8: SAVE SETTINGS AND RETURN TO NORMAL OPERATION MODE ................................................................................................22
FIGURE 6-9: ILLUSTRATION OF POOR AND GOOD ALIGNMENT ....................................................................................................................23
FIGURE 6-10: TRANSCEIVER ADDRESS SETTINGS .................................................................................................................................... 24
FIGURE 6-11: AUTO SPAN CALIBRATION READY TO START AFTER THE ZERO CALIBRATION IS COMPLETE........................................................... 25
FIGURE 6-12: SIGNAL STRENGTH LEDS INDICATE SUCCESSFUL AUTO SPAN CALIBRATION ......................................................................... 26
FIGURE 6-13: TRANSCEIVER IN NORMAL OPERATION MODE ......................................................................................................................27
FIGURE 6-14: SIGNAL STRENGTH LEDS SHOWING WHEN TO RELEASE ZERO TO ENTER SERVICE MODE ...................................................... 27
FIGURE 6-15: SERVICE MODE (FLASHING WARNING LED)......................................................................................................................... 28
FIGURE 6-16: SERVICE MODE (1 SIGNAL STRENGTH LED REPRESENTS 10 MINUTES ADDED TO DEFAULT SERVICE MODE)............................. 28
FIGURE 6-17: THE SERVICE MODE TIMER INDICATION MAX 60 MINUTES ..................................................................................................... 28
FIGURE 7-1: HOME MENU WITH 1CONFIGURED TRANSCEIVER ..................................................................................................................29
FIGURE 7-2: HOME MENU WITH 2CONFIGURED TRANSCEIVERS ................................................................................................................29
FIGURE 7-3: SENSOR MENU................................................................................................................................................................... 30
FIGURE 7-4: ALARM LIST MENU ............................................................................................................................................................... 31
FIGURE 7-5: SELECT AN ALARM IN THE ALARM LIST MENU ........................................................................................................................ 31
FIGURE 7-6: ALARM INFO SCREEN -E.G.NOT ALIGNED ALARM ..................................................................................................................32
FIGURE 7-7: TREND MENU ..................................................................................................................................................................... 34
FIGURE 7-8: PASSWORD POPUP WINDOW ................................................................................................................................................34
FIGURE 7-9: TRANSCEIVER SETUP.......................................................................................................................................................... 35
FIGURE 7-10: SYSTEM SETUP ................................................................................................................................................................ 36
FIGURE 12-1: INSTALLATION EXAMPLES .................................................................................................................................................. 50

Introduction
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1Introduction
1.1 About this Manual
This manual contains data and instructions for the installation, operation, and maintenance
of the Ex Opacity G26 system.
The main sections of the manual describe the general specifications, usage, maintenance,
installation and commissioning instructions, whereas the appendix in section 12 focuses
on details concerning Ex Safety.
The instructions are given in general terms and do not take into consideration a specific
installation. The figures used in the manual are only for general illustration purposes. This
manual is designed for the Ex Opacity G26 system delivered by Green Instruments A/S.
Note that each Ex Opacity G26 system is delivered with a default configuration from the
factory. Therefore, please study this manual and the Technical Drawings for each system
in their entirety for the operation of the system.
This manual does not describe all possible situations, but only the most common and
known situations. It cannot replace the necessary education and training of the personnel.
Should situations not described in this manual occur the operator should contact Green
Instruments A/S for instructions.
Attention
Before operation, read section 12 Appendix of Ex Opacity Transceiver , all instructions
and warnings within this manual and associated documentation.
Improper use may cause personal injury and/or damage of equipment and may void
the warranty. Green Instruments A/S disclaims any responsibility for damage and/or
injury caused by improper installation, use or maintenance of the equipment.
Green Instruments A/S reserves the right to minor alterations and improvements owing to
developments without being obliged to enter the corresponding changes in this manual.
Green Instruments A/S reserves the copyright of the manual. Without prior written permis-
sion of Green Instruments A/S, the manual may not be copied and given to unauthorized
people.

Ex-Opacity G26 System
Ver.2.1 – Revision March 2022 Page 7 of 56
1.2 Inquiries and Feedback
All claims and inquiries for spare parts shall be addressed to Green Instruments A/S or our
distributors. In all correspondence, or when ordering spare parts, please carefully state the
equipment type and serial number, which can be found on the label on the equipment.
Green Instruments A/S appreciates all feedback and suggestions for improvement. If any
questions appear or any discrepancies are found in this manual, kindly contact Green
Instruments:
Green Instruments A/S
Erhvervsparken 29
DK-9700 Brønderslev, Denmark
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.greeninstruments.com
1.3 About the System
The Ex Opacity G26 system is designed to detect small concentrations of oil mist in open
spaces and provide an early fire or explosion hazard warning.
The transceiver sends out a light beam with specific spectral characteristics that is projected
across the space to be monitored for oil mist leakage. The transceiver emits light that passes
through the space where it hits the reflector positioned opposite to the transceiver
The reflector returns the light to the transceiver and the transceiver detects the returned
amount of light. The transceiver compares the returned light with a reference light intensity
obtained during zero calibration. If the intensity of the returned light is reduced, then this
is an indication of oil mist or other particulate matters in the detected space. Based on this,
a warning or an alarm is given.
Please note that besides reacting to oil mist, the transceiver will also react to other
obstructions intercepting the light beam e.g. smoke and water mist. Consequently, an alarm
might be triggered and depending on the application, this might be perceived as "a false
alarm". However, in this scenario, such an alarm will typically indicate another type of
malfunction that would require attention.

Introduction
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1.3.1 System Components
As a standard configuration, the Ex Opacity G26 system consists of the following standard
elements:
Control and Monitoring Unit
The control and monitoring unit is arranged with a touchscreen, connection terminals and
cable glands. The control and monitoring unit can be configured to monitor up to 2 trans-
ceivers.
Transceiver/Reflector Unit
The transceiver contains the laser source, optical components, electronics and data proces-
ser capacity to control and shape the laser beam projected across to the reflector. The trans-
ceiver is mounted in the Ex Opacity Transceiver Mounting module G26 for easy installa-
tion.
The Ex Opacity G26 system is delivered with a standard 15m Ex connection cable. The
reflector reflects the light back to the Transceiver where the light attenuation is measured.
The reflector module contains a precision reflector to direct the light beam back to the
transceiver.
1.3.2 Additional Components
•Ex Junction Box (JB) can be used in the Ex Zone to connect customer supplied cables
with the cable used to connect to the transceiver.
•Ex Interface Cabinet with intrinsic safety barriers for power supply and communication
between the monitor unit and the transceiver.

Ex-Opacity G26 System
Ver.2.1 – Revision March 2022 Page 9 of 56
2Specifications
Control and Monitoring Unit
Power Supply Input
Option 1: 100…240 VAC –50/60 Hz –1.4 A
Option 2: 20…30 VDC –2 A
Ambient Temperature
0…55°C
Communication Options:
(All included as Standard)
Analog output:
2 x 4…20 mA max. 500 Ω - (active & linearized)
Digital output: 4 x Alarm Relays
Bus: Modbus TCP/IP
Alarm Levels
Alarm level is configurable
Warning level is default set at 50% of Alarm level
Alarm Delay
Default 0 s
(Programmable 0…1800 s)
Display
Opacity level [%]
Accuracy
≤ 1 % of full scale for distance 0.5…9.0m
≤2 % of full scale for distance 9.0…15.0m
Dimensions/Weight
Refer to Installation Layout
Enclosure
IP 65 Steel box
Transceiver
Measurements
Opacity
Measuring Principle
Transmission double pass
Measuring Range (FS)
0…100% Opacity
Accuracy
+/-1% of full scale (FS) for 0,5…9.0 m
+/-2% of full scale (FS) for 9.0…15.0 m
Scanning Distance
Optimal: 2.0…9.0 m
Possible: 1.0…15.0 m
Power Supply
24 VDC +/- 10%
Communication Interface
Modbus RTU server
Ambient Temperature
-25…55°C
(For Ex-application according to IEC 60079-0)
Class C
-25…45°C (For Marine application)
Humidity
Above dew point
Vibration
Class B
EMC
Class A (EN 61326-1 Table 2)

Specifications
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Enclosure
Class B/IP 54
Dimensions & Weight
Refer to Installation Layout
Materials
SS316
Reflector
Ambient Temperature
-25…55°C (For Ex-application according to IEC 60079-0)
Class A
5…45°C (For Marine application)
Humidity
Above dew point
Vibration Class
Class B
Enclosure Class
Class B/IP 54
Dimensions & Weight
Refer to Installation Layout
Materials
EN-AW 6082, Acryl Reflector
Optional Equipment (refer to spare part)
Ex Interface Cabinet
Protection Method
Ex ib (connections to Ex Zone)
Material
Steel
Enclosure Class
IP 54
Intrinsic Safe Power Supply
Uo = 23.6V, Io = 176.4 mA, Po = 1038 mW, Co = 0.97 uF,
Lo = 4.5 mH
Intrinsic Safe
Communication Interface
Uo = 3.7V, Io = 93 mA, Po = 85 mW
Ex Junction
Protection Method
Ex e
Cable to Transceiver
Ex Junction box is delivered with 15m pre-configured cable
for easy connection to the Transceiver.
Materials
Fiberglass Reinforced Polyester (FRP)
Enclosure Class
IP 54
Audit Targets
100, 22 & 8 % Opacity (+/÷ 2% of full range)
Useable for field validation
Only use in Ex zone when Ex zone is safe.
Approvals and Certificates
Download all product certificates at https://greeninstruments.com/