Land 4500 MKII Premier User manual

Operation and Maintenance Manual
Model 4500 Premier
Publication No 770.084
Language English
Combustion & Environmental Monitoring

How to Get Further Assistance
If further assistance is required please contact your nearest Land Instruments International office at the following
addresses or your local distributor (see our web site for details http://www.landinst.com).
When contacting Land please have the following information available:
Instrument Serial Number .....................
Instrument Part Number ........................
Instrument Name and Model.................
Power supply, voltage and frequency ...
This information is found on the rating plate of each instrument.
UK
Land Instruments International
Dronfield,
Derbyshire, S18 1DJ
Tel: [phone]
Fax: [phone]
E-Mail:[email protected]
Web: www.landinst.com
USA
Land Instruments International Inc.
10 Friends Lane
Newtown, PA 18940-1804
Tel: [phone]
Fax: [phone]
E-Mail:[email protected]
Web: www.landinstruments.net
Poland
Land Instruments Sp z o.o.
ul. Michalowskiego 5/2
31 - 126 Krakow
Tel: [phone]
Fax: [phone]
E-Mail:[email protected]
Web: www.land.com.pl
Italy
Land Instruments SRL
Via dell’Industria, 2
20037 Paderno Dugnano MI
Tel: [phone]
Fax: [phone]
E-Mail:[email protected]
France
Land Instruments Sarl
7 Parc des Fontenelles
78870 Bailly
Tel: [phone]
Fax: [phone]
E-Mail:[email protected]
Mexico
Land Instruments International
Paseo de la Refoma
No 350 Piso 11
Col Juarez DF CP06600
Tel + 52 55 9171 1466
Fax + 52 55 9171 1499
E-Mail:[email protected]

Equipment Operation
Use of this instrument in a manner not specified by Land Instruments International may be hazardous.
Electrical Power Supply
Before working on the electrical connections all of the electrical power lines to the equipment must be isolated. All the
electrical cables and signal cables must be connected exactly as indicated in these operating instructions. If in doubt
contact Land Instruments International.
Face & Eye Protection
Suitable face and eye protection must be worn when working on hot vessels and ducts!
Special safety measures must be taken when working on a high-pressure 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
IMPORTANT
If any item has been damaged in transit, this should be reported to the carrier and to the supplier immediately. Damage
caused in transit is the responsibility of the carrier not the supplier.
DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save the packing
with the damaged article for inspection by the carrier.
Return of Goods for Repair
If you need to return goods for repair please contact our Customer Service Department. They will be able to advise you
on the correct returns procedure.
Any item returned to Land Instruments International should be adequately packaged to prevent damage during transit.
You must include a written report of the problem together with your own name and contact information, address, telephone
number, email address etc.
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.
Health and Safety Information

Design and Manufacturing Standards
Dimensions
Unless otherwise stated, all measurements are given in millimetres and inches.
The Quality Management System of Land Instruments International approved to BS EN ISO 9001
for the design, manufacture and on-site servicing of combustion, environmental monitoring and non-
contact temperature measuring instrumentation. Associated software is designed and developed in
accordance with TickIT.
This instrument complies with current European directives relating to Electromagnetic Compatibility
89/336/EEC and Low Voltage Directive 73/23/EEC.
Operation of radio transmitters, telephones or other electrical/electronic devices in close proximity to
the equipment while the enclosure doors of the instrument or its peripherals are open, may cause
interference and possible failure where the radiated emissions exceed the EMC directive.
The protection provided by both CE and IP classifications to this product may be invalidated if
alterations or additions are made to the structural, electrical, mechanical or pneumatic parts of this
system. Such changes may also invalidate the standard terms of warranty.
Observe precautions for handling electrostatic discharge sensitive
devices
Caution, risk of electric shock.
Caution, attention to possibility of risk of damage to the product,
process or surroundings. Refer to instruction manual.
Protective Conductor Terminal.
Caution, hot surface
This item or material can be recycled.
Signs and Symbols Used on Equipment and Documentation
Copyright
This manual is provided as an aid to owners of a Land Instruments International’s products and contains information
proprietary to Land Instruments International. This manual may not, in whole or part, be copied, or reproduced without the
expressed written consent of Land Instruments International Ltd.
©Copyright 2002 Land Instruments International.

REV 2 December 2003 publication number 770.084
Contents
Ref. Description Page
Design and Manufacturing Standards 5
Signs and Symbols Used on Equipment and Documentation 5
INSTALLATION
Ref. Description Page
A1 General Description 11
A2 Installation Diagram 13
A3 Installation Instructions 14
A3-1 Installation Checklist 14
A3-2 Selecting an Installation Location 15
A3-3 Maintaining the Measurement Pathlength During Installation 16
A3-4 Installing the Mounting Flanges 16
A3-5 Mounting Details 18
A3-6 Using the Flange Alignment Tool 19
A3-7 Important Information for Installing the Transceiver and Retro-Reflection 20
A3-8 Mounting the Transceiver and Retro-Reflector 21
A3-9 Installing the Termination Box 22
A3-10 Electrical Connections 23
A3-11 Cable Specification 24
A3-12 Termination Box Connections 25
A3-13 Control Room Unit Connections 26
A3-14 MODBUS Connections 27

OPERATION
Ref. Description Page
B1 Getting Started 29
B1-1 The User Interface 29
B1-2 Function Keys 30
B1-3 Glossary of Terms 31
B1-4 Using the Instrument for the First Time 32
B2 Normal Modes of Operation 48
B2-1 Alarm Setup 48
B2-2 Output Setup 50
B2-3 MODBUS Communications 55
B3 Periodic Modes of Operation 64
B3-1 Calibration Check 64
B3.2 Calibration Audit 65
B3-3 Re-calibration 67
B3-4 Isokinetic Calibration 68
B3-5 M203 Clear Stack Simulator 72
B3-6 M203 Clear Stack Simulator Calibration 77
B3-7 Zero Point Reflector Adjustment 80
B3-8 Upscale Span Filter Adjustment 84

REFERENCE
Ref. Description Page
C1 Theory of Operation and Application 87
C1-1 General Outline 87
C1-2 Beer-Lambert’s Law 88
C1-3 Optical Pathlength Ratio (OPLR) 89
C1-4 Examples of Different Optical Pathlength Ratios (OPLR) 91
C2 Requirements for Environmental Legislation 92
C3 Physical Principles 93
C3-1 General Description 93
C3-2 Principle of Operation 94
C4 User Interface 96
C4-1 Operational Structure 96
C4-2 Faults Screens 97
C4-3 Calibration Screens 98
C4-4 Setup Screens 104
C4-5 Display Screens 118
C4-6 Parameter Screens 120
C5 System Specification 121
C5-1 4500 Premier Dust and Opacity Monitor 121
C6 Testing and Checking 124
C6-1 Identifying Faults 124
C6-2 Maintenance 126
C6-3 Replacement Parts and Consumables 130
C7 Configuration Record Sheet 134
APPENDIX
Appendix A Aperture and Grating Selection Tables 137
AppA-1 Automatic Zero Point Reflector Aperture and Grating Selection 137
AppA-2 Span Filter Grating Selection 137
Appendix B Low Temperature Termination Box 138
AppB-1 Termination Box Heater Unit 138
STANDARD TERMS OF WARRANTY

Model 4500 Premier Dust and Opacity Monitor
11
A1 General Description
The Model 4500 Premier is designed for continuous operation in all weather conditions. Maintenance
requirements are minimal.
The Land Instruments International Model 4500 Premier Continuous Opacity Monitoring System (COMS)
measures opacity by shining a light beam through flue gases.
An internal microprocessor calculates dust density and other parameters.
Transceiver Containing all of the major electronic and electro–optic components.
Retro-Reflector Containing a corner cube reflector.
Termination Box For customer terminations.
Air Purge System A continuous supply of purge air essential to prevent dust and
(Not shown) corrosive gases from affecting the optical system. Single and dual
electric blowers or compressed-air driven devices are available to
suite individual site requirements. Automatic fail–safe shutters can
also be fitted for temporary protection in the event of a purge air
failure.
Control Room Unit A remote data display unit. (optional)
Weatherproof Cover For full environmental protection. (optional)
Control Room Unit
Retro-Reflector
Termination Box
Transceiver

Model 4500 Premier Dust and Opacity Monitor
12
Analogue Output
The Model 4500 Premier Dust and Opacity Monitor has two current loop outputs available. Each one
may be set independent of the other to output one of the six functions below:
Opacity Dust
Constant Current Calibration Drift
Optical Path Length Ratio Optical Density
All the options can be set to ‘TRACK’or ‘HOLD’the measurement signal during calibration routines. If
‘TRACK’is set, the measurement signal will continue to be output during calibration and if ‘HOLD’is
set the measurement signal will remain at the last recorded reading before calibration until the calibration
routine is complete.
Relay Outputs
Located on the key panel of the 4500 Premier are five LEDs which light to indicate the operation of the
following relay outputs:
SYSTEM OK
ZERO CALIBRATION
SPAN CALIBRATION
2 ALARMS
Remote Calibration Initiation
Calibration of the monitor may be initiated remotely from a Control Room Unit. (Part number Panel
Mount 099.437 or Wall Mount 703.880) or via a contact closure.
Computer Interface Operation
The Model 4500 Premier Dust and Opacity Monitor may be connected to a computer or data acquisition
system via an RS232 or RS485 Modbus interface inside the Termination Box.

Model 4500 Premier Dust and Opacity Monitor
13
A2 Installation Diagram
The Model 4500 Premier Dust Opacity Monitoring System showing all components installed.
1 Model 4500 Premier Transceiver
2 Model 4500 Premier Retro-Reflector
3 Termination Box
4 Air Blower Unit with Filters
5 Umbilical Cable
6 Customer Alarms
7 Instrument Power Input
8 Input and Output Signals
9 Blower Pressure Switch Trip Output
13
1 2
3
4
5
9
CAUTIONDANGER
7
8
10
OPACITY & DUST MONITOR
CALIBRATE
SYSTEM OK
SPAN CAL IBRATE
ZERO CALIBRAT E
ALARM 11
6
12
14
14
15
10 Control Room Unit (CRU)
11 Control Room Unit (CRU) Power Input
12 Blower Power Supply
13 Retransmitted alarm contacts
14 External power isolator with overcurrent
protection
Important
An external circuit breaker incorporating over-current protection or a power
isolator and fuse must be fitted.

Model 4500 Premier Dust and Opacity Monitor
14
A3 Installation Instructions
A3-1 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.
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.
5 Install the Termination Box and prepare gland plate for power and signal connection cables. An
external power isolator is required.
6 Route all signal and power cables.
7 Connect the power supply to the Air Blower Unit(s).
8 Connect the electrical power supply and signal cables to Termination Box and instrument.
9 Power up air purge system.
10 Install and connect the Control Room Unit (see Control Room Unit Instruction Manual for full
details) or any other output devices to Termination Box (ie chart recorder, display unit etc). An
external power isolator is required.
11 Check continuity of protective earth.
12 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.
13 Power up the instrument and calibrate it.
Caution
Risk of damage to
equipment
Warning
Risk of electric shock.

Model 4500 Premier Dust and Opacity Monitor
15
A3-2 Selecting 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, it is critical that the best possible location be selected. The Transceiver
should be mounted so that it can detect a representative concentration of dust across the stack
or duct diameter.
2 If the monitor is to be used for US regulatory compliance the location should be determined by
the EPA installation specifications detailed in 40 CFR 60, Appendix B, Specification 1, or a
location approved by the appropriate agency.
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 Measurement errors may result if the Transceiver is subjected to strong vibrations or if the
stack or duct changes shape as the gas temperature changes. If this cannot be avoided, a
vibration free mounting can be installed. Contact Land for information.
6 The ambient temperature at the mounting location must remain between -20°C and +55°C
(-4°F and 131°F). If necessary, heating, ventilation, or isolation should be used to ensure this
temperature range is not exceeded.
7 If the duct walls are too thin to support the weight of the instrument, additional reinforcement
will be required.
8 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 or perpendicular to the direction of
gas flow.
mounting flange
for instrument
access platform
stack

Model 4500 Premier Dust and Opacity Monitor
16
A3-3 Maintaining the Measurement Pathlength During Installation
The flange-to-flange pathlength is defined as the distance between the Transceiver air purge flange and
the Retro-Reflector air purge flange.
The flange-to-flange pathlength is specified at the time of order and is factory set.
This measurement pathlength is indicated on the back of the Transceiver.
During the welding and alignment procedures the flange-to-flange measurement path must not
differ by more than ±1%. Failure to do so will affect the accuracy of the measurement readings.
A3-4 Installing the Mounting Flanges
The Model 4500 Premier is supplied with two mounting flanges (specially adapted 3" ANSI) with stand-
offs (sleeves) used to mount the Transmissometer onto the stack or duct.
1 Each flange is 240mm (9.45") 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 (0.25"
to 0.50")
Transceiver
Air Purge Flange Retro-Reflector
Air Purge Flange
flange-to-flange path length

Model 4500 Premier Dust and Opacity Monitor
17
6 Position the Transceiver mounting flange with the “TOP”label in the 12 o'clock position and
tack weld the mounting flange in place.
Accurate positioning of the flange at this stage is critical to the operation of the instrument.
If the flange is not parallel to the stack wall it will be impossible to align the instrument
correctly.
7 Cut a hole around the Retro-Reflector pilot hole, large enough to allow eventual welding of the
outside of 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 2 m / 6.5 ft) and easily accessible the flanges can be
aligned using a straight piece of tube.
a Slide the tube through both flanges. Ensuring the specified flange-to-flange measuring
path is maintained to within ±1%.
b Tack weld the Retro-Reflector mounting flange in place.
cMake any necessary adjustments to the Transceiver mounting flange to ensure
alignment between the two flanges is maintained. Weld the flange permanently in place.
d Make any necessary adjustments and weld the Retro-Reflector mounting
flange permanently in place.
If the diameter of the stack is too large (over 2 m / 6.5 ft) to use an alignment tube, Land can
supply an optical flange alignment tool (Part number 702.787). Contact Land for more information.
TOP

Model 4500 Premier Dust and Opacity Monitor
18
A3-5 Mounting Details
Air Purge Mounting Holes
The air purge unit must be fixed to the mounting flange. It has three mounting holes to accept the
mounting studs from the Standpipe.
ø190 (7.50)
Front view of Air Purge showing mounting holes

Model 4500 Premier Dust and Opacity Monitor
19
A3-6 Using the Flange Alignment Tool
The flange alignment tool (part number 702.787) consists of two plates which are mounted on to the
flanges. One plate supports a light source, the other a small telescope with a target in the centre. When
the flanges are properly aligned, the light spot is located in the centre of this target.
The flange alignment tool is used as follows:
1 Remove the 12 washers from the mounting flanges, retain these as they are essential to the
correct installation of the instrument.
2 Tack weld the flanges in position.
3 Mount the flange alignment tool as shown above.
4 Align flange number 1 and weld it into place.
5 Reverse the flange alignment tool (switch components).
6 Align flange number 2 and weld it into place.
7 Replace the washers, see section A3-7 installation details.
Flange 1Flange 2
Light Source
Light Source Alignment Circle
reinforcement if
required

Model 4500 Premier Dust and Opacity Monitor
20
A3-7 Important Information for Installing the Transceiver and Retro-Reflection
Standard Dimensions with Fail-safe Shutters fitted
1 Transceiver 5 Flange-to-flange Path Length
2 Retro-Reflector 6 Transceiver open for calibration audit
3 Air Purge Entry 7 Retro-Reflector open for inspection
4 Umbilical connector
1 Check the dimensions carefully before installation.
a Allow at least 1 m (3.3 ft) for mounting and removal procedures
b Allow a minimum of 150 mm (6 ") directly below the instrument for purge air (3) and
electrical connections (4).
cAllow sufficient space to the side of each instrument to allow the hinges (6
and 7) to be opened.
d 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 7 m (23 ft).
3 The termination box (see the diagram in section A2) must be mounted within 2 m (6.6 ft) of the
Transceiver to allow the interconnecting cable (4) to reach. Make sure that there is sufficient
cable to allow the inspection covers (6 and 7) to be opened and closed without disconnecting
the cable.
4 The flange-to-flange path length (5) is factory set and must not be changed. It is given on the
back of the Transceiver.
638 (25) 240 (10) 440 (17)
220 (9)
150 (6) 220 (9)
240 (10) 1000 (39) 1000 (39)
690 (27)
500 (20)
4
6
7
5
1 2
3 3
420 (16.5)
160 (7)
220 (9)
220 (9)
W 220 (9)
3
520 (20.5) 240 (10) 320 (13)
220 (9)
150 (6) 220 (9)
240 (10) 1000 (39)
34
1000 (39)
580 (23)
420 (16.5)
6
500 (20)
160 (7)
150 (6)
5
1 2
7
220 (9)