GREEN INSTRUMENTS G16 User manual

G16
Smoke Density Monitor
Instruction Manual
Document ID number.: 02891

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G16 Smoke Density Monitor
Ver.2.4 – Revision March 2022 3
Contents
CONTENTS..............................................................................................................3
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 .........................................................................................7
1.3.2 Optional components........................................................................................8
2SPECIFICATIONS.................................................................................................9
3SAFETY ASPECTS ............................................................................................11
4CONTROL AT DELIVERY.....................................................................................13
5INSTALLATION ..................................................................................................14
5.1 IN GENERAL.....................................................................................................................14
5.2 STANDARD INSTALLATION..................................................................................................15
5.2.1 Welding Sockets – Pre-alignment ..................................................................17
5.2.2 Support and Alignment Brackets (Optional) ...................................................17
5.2.3 Air modules, Transceiver and Reflector .........................................................18
5.2.4 Audit Module...................................................................................................18
5.2.5 Purge Air System............................................................................................19
5.2.6 Control and Monitoring Unit............................................................................20
5.2.7 Junction Box (Optional) ..................................................................................20
5.3 ELECTRICAL CONNECTIONS ..............................................................................................23
5.3.1 Control and Monitoring Unit............................................................................23
5.3.2 Junction box (optional) ...................................................................................23
5.3.3 Cable types.....................................................................................................23
6MENU STRUCTURE & CONFIGURATION...............................................................24
6.1 TRANSCEIVER ..................................................................................................................24
6.1.1 Transceiver Button Function...........................................................................24
6.1.2 Set Laser Aligning Function............................................................................25
6.1.3 Set Unit Address.............................................................................................26
6.1.4 Save New Settings .........................................................................................27
6.1.5 Calibration ......................................................................................................28
6.2 CONTROL AND MONITORING UNIT......................................................................................28
6.2.1 Home Menu ....................................................................................................29
6.2.2 Sensor Menu ..................................................................................................30
6.2.3 Alarm List Menu..............................................................................................30
6.2.4 Trend Menu ....................................................................................................34
6.2.5 Sensor Setup..................................................................................................34
6.2.6 System Setup .................................................................................................36
7CALIBRATION...................................................................................................38

Contents
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7.1 ZERO CALIBRATION .......................................................................................................... 38
7.2 AUTO SPAN CALIBRATION ................................................................................................. 38
7.3 SPAN CALIBRATION ..........................................................................................................38
8COMMISSIONING ..............................................................................................40
8.1 START OF THE SYSTEM..................................................................................................... 40
8.2 CALIBRATION................................................................................................................... 40
8.3 SETTING OF ALARM LEVELS .............................................................................................40
8.4 SETTING OF SIGNAL OUTPUTS ..........................................................................................40
9MAINTENANCE .................................................................................................41
10 TROUBLESHOOTING .........................................................................................42
11 SPARE PARTS..................................................................................................43

G16 Smoke Density Monitor
Ver.2.4 – Revision March 2022 5
Table of Figures
FIGURE 5-1: INSTALLATION OF THE G16 SMOKE DENSITY MONITOR 16
FIGURE 5-2: MOUNTING OF A SUPPORT AND ALIGNMENT BRACKET 17
FIGURE 5-3: MOUNTING OF AIR MODULE, AUDIT MODULE (OPTIONAL) AND TRANSCEIVER 18
FIGURE 5-4: MOUNTING OF AIR MODULE AND REFLECTOR 19
FIGURE 5-5: INSTALLATION OF THE CONTROL AND MONITORING UNIT 21
FIGURE 5-6: INSTALLATION OF THE JUNCTION BOX 22
FIGURE 6-1: TRANSCEIVER INTERFACE 24
FIGURE 6-2: ILLUSTRATION OF STRONG SIGNAL, NO OBSTRUCTIONS TO THE LIGHT BEAM 24
FIGURE 6-3: ILLUSTRATION OF WEAK SIGNAL, OBSTRUCTIONS TO THE LIGHT BEAM 25
FIGURE 6-4: ILLUSTRATION OF POOR AND GOOD ALIGNMENT 26
FIGURE 6-5: TRANSCEIVER ADDRESS SETTINGS 27
FIGURE 6-6: THE AUTOMATIC SPAN CALIBRATION ACTIVE AFTER ZERO CALIBRATION 28
FIGURE 6-7: AUTOMATIC SPAN CALIBRATION ACCEPTED 28
FIGURE 6-8: HOME MENU WITH 1 CONFIGURED SENSOR - SENSOR MENU 29
FIGURE 6-9: HOME MENU WITH 2 CONFIGURED SENSORS 29
FIGURE 6-10: ALARM LIST MENU 31
FIGURE 6-11: SELECT AN ALARM IN THE ALARM LIST MENU 31
FIGURE 6-12: ALARM INFO SCREEN - E.G, NOT ALIGNED ALARM 32
FIGURE 6-13: TREND MENU 34
FIGURE 6-14: PASSWORD POPUP WINDOW 35
FIGURE 6-15: SENSOR SETUP 35
FIGURE 6-16: SYSTEM SETUP 37

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 G16 Smoke Density Monitor.
The instructions are given in general terms and do not take into consideration a specific
installation. As such, the instruction manual is designed for the Opacity Monitor delivered
by Green Instruments A/S.
Note that each Smoke Density Monitoring System is configured at the factory ac- cording
to specifications. Therefore, it is important to study this manual and the Technical Draw-
ings for each system in their entirety for the installation, operation and maintenance of the
system.
The 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 that cannot be solved in accordance with
normal known practice and good workmanship, the operator should contact Green Instru-
ments A/S for instructions.
This manual does not claim to cover all details or variations in equipment or to provide for
every possible contingency that may arise during installation, operation, or maintenance.
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
Attention
Before operation read 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.

G16 Smoke Density Monitor
Ver.2.4 – Revision March 2022 7
1.2 Inquiries and Feedback
All claims and inquiries for spares 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 can be found in this manual, kindly contact Green
Instruments:
Green Instruments A/S
Erhvervsparken 29
DK-9700 Brønderslev
Denmark
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.greeninstruments.com
1.3 About the System
1.3.1 System components
As a standard configuration, the G16 Smoke Density Monitor consists of the following
standard elements:
Control and Monitoring Unit (HMI)
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
•A G16 Smoke Density Monitor can be configured with up to 2 Transceiver/Reflector
Units. Each transceiver/reflector unit consists of:
•A G16 transceiver module assembly, which contains the laser source, optical compo-
nents, electronics, and data processing capacity. The transceiver controls and shapes
the laser beam projected across the measuring area to the reflector assembly and
measures the light attenuation when the light is reflected.
•An air module, which provides a purge air boundary between the process and the opti-
cal area and serves two main purposes: (i) Avoiding soiling of the optical parts from
the exhaust gases. (ii) Thermal protection of the instrument against exhaust gases.

Introduction
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•The air module is arranged with purge air supply connection and flow control valve for
optimal airflow adjustment.
•A sealing air system including 9m purge air hose and a purge air distributor.
•A G16 reflector module assembly, which contains a precision reflector to direct the
light beam back to the transceiver assembly.
•A connection cable of 15 m for connection between the transceiver and the control and
monitoring unit.
•Two welding sockets 1” for the transceiver and the reflector assemblies.
Download the product certificates at https://greeninstruments.com/
1.3.2 Optional components
•Junction box (JB): if the connection cable between the transceiver assembly and the
control and monitoring unit is required to be more than 15 m, there shall be a junction
box to support the connection between the transceiver and the control and monitoring
unit.
•Audit Module Assembly Audit targets
•Sealing air compressor with filter
•Extended monitoring system supporting up to 16 transceivers

G16 Smoke Density Monitor
Ver.2.4 – Revision March 2022 9
2Specifications
Control and Monitoring Unit
Display
Opacity level [%]
Accuracy
Better than 2 % of full scale
Precision
Better than 2 % of full scale
Power supply Input
24 VDC –2 A (optional: 100–240 VAC –50/60 Hz –
1.4 A)
Communication
Modbus TCP/IP
Analog Output
2 x 4…20 mA max. 500 Ω - active & linearized
Alarm relay outputs
4 x alarm relays Potential free. Imax = 3A. Umax =
250VAC
Alarm levels
Alarm level is configurable
Warning level is automatic set at 50% of the alarm level
Alarm delay
Default 0 s (programmable 0–1800 s)
Ambient temperature
0°C –55°C
Dimensions/weight
H×W×D: 300 × 200 × 150 mm / 5.5 kg
Enclosure
IP 65 Steel box, AISI 1008, painted RAC 7035
Recommended minimum
cable size
Power supply: 3 × 1.5 mm² shieldedcables
Signal cable: 2 × 1.0 mm² twisted pair shielded
cables Alarm cable: 4 × 1.0 mm² shielded cables
Network cable: Cat5e
Transceiver incl. Air Module
Measurements
Opacity
Measuring principle
Transmission dual pass
Measuring range
0 –100% Opacity
Scanning distance
0.5 to 10.0 m
Power supply
24 VDC +/- 10%
Purge air supply
5-10 NLPM. Air quality to meet ISO 8573-1 Class 3
Flue gas temperature
Above dewpoint up to 460°C
Flue gas pressure
-500 to + 500 hPa

Specifications
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Ambient temperature
0°C –55°C (Class A)
Vibration Class
B
EMC Class
A
Enclosure Class
B/IP 66
Dimensions & weight
OD 75 mm, length 220 mm, 1800g
Reflector incl. Air Module
Purge air supply
5-10 NLPM. Air quality to meet ISO 8573-1 Class 3
Flue gas temperature
Above dewpoint up to 460°C
Flue gas pressure
-500 to + 500 hPa
Ambient temperature
0°C –55°C (Class A)
Vibration Class
B
Enclosure Class
B/IP 66
Dimensions & weight
OD 75 mm, length 143 mm, 1500g
Optional Equipment
Sealing/purge air compressor
Support and alignment brack-
ets
Support and alignment brackets
Audit module
Audit module
Audit targets
Audit targets
Visualization, recorder, and
data logging
Visualization, recorder and data logging
Remote digital display for
panel mounting
Remote digital display for panel mounting
Approvals and Certificates
Download all product certificates at https://greeninstruments.com/
Specifications are subject to changes without notice.