Mip Lm 3086 epa3 Operation manual

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

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Business ID: 1627111-2

EU VAT ID: FI16271112

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MIP LM 3086 EPA3

MIP LM 3086 SE

Laser Opacity and Dust Monitors

Operation and service manual

LASER OPACITY MONITOR

LM 3086 EPA 3

ZERO

CHECK

SPAN

CHECK

WINDOW

CHECK

ALARM

CHECK

STATUS

CHECK

ZERO

MODE

SPAN

MODE

WINDOW

LIMIT

WARMING

LIMIT

ALARM

LIMIT

PURGE

FAULT SYSTEM

FAULT

SET-UP KEYS

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

WWW.MIP.FI

Aanitasomittarit.fi

Langatonmittaus.fi

Mikrofonit.fi

Opacitymonitors.fi

MIP Electronics Oy

Palokorvenkatu 2

04250 KERAVA, FINLAND

Business ID: 1627111-2

EU VAT ID: FI16271112

+358 10 3222 631

[email protected]

COMPANY INFORMATION

MIP Electronics Oy Telephone: +358-10 3222 631

http://www.mip.fi/ (Monday-Friday 8:00 am to 4.00 PM, GMT+2 hours)

Postal Address: e-Mail:

MIP Electronics Oy Commercial: [email protected]

Palokorvenkatu 2 Technical: support@mip.fi

04251 Kerava

Finland

 MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018 
 
 Page 1 / 105 
 
 
 
WWW.MIP.FI 
Aanitasomittarit.fi 
Langatonmittaus.fi 
Mikrofonit.fi 
Opacitymonitors.fi 
MIP Electronics Oy 
Palokorvenkatu 2 
KERAVA, FINLAND 
Business ID: 1627111-2 
EU VAT ID: FI16271112 
+358 10 3222 631 
[email protected] 
Table of content 
1MONITOR DESCRIPTION ........................................................................................................................... 4 
1 INTRODUCTION ....................................................................................................................................... 4 
1.1 BASIC DEFINITIONS ............................................................................................................................. 4 
1.2 SINGLE PASS VS. DOUBLE PASS........................................................................................................... 5 
1.3 CHARACTERISTICS OF THE LIGHT SOURCE .......................................................................................... 6 
1.4 CHARACTERISTICS OF THE BEAM GEOMETRY .................................................................................... 6 
1.5 CHARACTERISTICS OF THE LIGHT RECEIVER........................................................................................ 6 
1.6 MAINTENANCE AND AUDIT PROCEDURE ADVANTAGES .................................................................... 7 
1.7 SUMMARY OF LASER BASED OPACITY BENEFITS ................................................................................ 8 
2 MONITOR PARTS DESCRIPTION ............................................................................................................... 8 
2.1 LASER UNIT LM3086 EPA3 .................................................................................................................. 9 
2.2 LASER UNIT LM3086 SE..................................................................................................................... 11 
2.3 RECEIVER UNIT R 3086EPA3/SE ........................................................................................................ 13 
2.4 CONTROLLER UNIT M3086EPA3/SE.................................................................................................. 14 
3 SYSTEM INTERCONNECTIONS................................................................................................................14 
4 MONITOR SPECIFICATIONS....................................................................................................................14 
4.1 LASER (TRANSMITTER) UNIT SPECIFICATION.................................................................................... 15 
4.2 RECEIVER UNIT SPECIFIC SPECIFICATIONS ........................................................................................ 15 
4.3 CONTROLLER UNIT SPECIFICATIONS................................................................................................. 15 
4.4 CONTROLLER RESOLUTION ............................................................................................................... 16 
4.5 POWER REQUIREMENTS................................................................................................................... 16 
4.6 OPERATION ENVIRONMENT ............................................................................................................. 16 
2MONITOR DISPLAYS AND CONTROLS.......................................................................................................16 
1 LASER UNIT CONTROLS..........................................................................................................................16 
1.1 RECEIVER UNIT CONTROLS ............................................................................................................... 17 
1.2 CONTROLLER UNIT DISPLAYS AND CONTROLS ................................................................................. 17 
1.3 AUTOMATIC SHUTTER GATE............................................................................................................. 17 
2 MONITOR MODES OF OPERATION ........................................................................................................17 
2.1 CONTROLLER DIAGNOSTIC MODES .................................................................................................. 18 
2.2 RUN-TIME DIAGNOSTICS .................................................................................................................. 19 
2.3 MAIN MONITORING MODE .............................................................................................................. 20 
2.4 AUTO ZERO MODE............................................................................................................................ 20 
2.5 AUTO SPAN MODE............................................................................................................................ 21 
2.6 SERVICE MODES................................................................................................................................ 26 
2.7 ADDITIONAL SUB MENUS FROM DYNAMIC MODE .......................................................................... 33 
3INSTALLATION AND START-UP.................................................................................................................35 
1 PRE-INSTALLATION TESTS...................................................................................................................... 35 
2 INSTALLATION SITE REQUIREMENTS ..................................................................................................... 35 
2.1 TURBULENCE AND EFFLUENT MIXING.............................................................................................. 35 
2.2 PRESSURE CONSIDERATIONS............................................................................................................ 35 
2.3 VIBRATION AND ALIGNMENT ........................................................................................................... 36 
2.4 TEMPERATURE AND MOISTURE ....................................................................................................... 36 
3 CROSS-STACK ALIGNMENT CHECK......................................................................................................... 36 
4 CALIBRATION/LINEARITY CHECK............................................................................................................37 
5 EPA FIELD CERTIFICATION TESTS DURING START-UP.............................................................................37 
4MAINTENANCE AND SERVICE...................................................................................................................38 
1 SELF-DIAGNOSTIC TEST..........................................................................................................................38 

 MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018 
 
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WWW.MIP.FI 
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Business ID: 1627111-2 
EU VAT ID: FI16271112 
+358 10 3222 631 
[email protected] 
2 DIRT ACCUMULATION TEST ................................................................................................................... 38 
2.1 CLEANING THE OPTICS...................................................................................................................... 38 
3 CROSS-STACK ALIGNMENT CHECKS.......................................................................................................39 
4 HARDWARE DIAGNOSTICS IN THE LASER UNIT......................................................................................40 
5 INSTALLATION INSTRUCTIONS............................................................................................................... 40 
5APPENDIXES.............................................................................................................................................41 
1 APPENDIX A: ROUTINE MAINTENANCE..................................................................................................41 
1.1 OVERVIEW ........................................................................................................................................ 41 
1.2 DAILY CHECKS ................................................................................................................................... 42 
1.3 PERIODIC CHECKS ............................................................................................................................. 42 
1.4 IRREGULAR CHECKS .......................................................................................................................... 42 
2 APPENDIX B: CLEANING THE OPTICS...................................................................................................... 43 
2.1 OVERVIEW ........................................................................................................................................ 43 
2.2 RECEIVER SIDE / CLEANING A DIRTY WINDOW ................................................................................ 43 
2.3 TRANSMITTER SIDE........................................................................................................................... 47 
3 APPENDIX C: LASER UNIT REPLACEMENT AND ALIGNMENT PROCEDURES ...........................................49 
3.1 OVERVIEW ........................................................................................................................................ 49 
3.2 REPLACEMENT LM 3086EPA3........................................................................................................... 49 
3.3 REPLACEMENT LM 3086SE ............................................................................................................... 52 
3.4 ALIGNMENT ...................................................................................................................................... 53 
3.5 CLEAR STACK PROCEDURE ................................................................................................................ 54 
4 APPENDIX D: E-PROM REPLACEMENT ...................................................................................................55 
4.1 E-PROM REPLACEMENT FOR THE MONITOR UNIT ........................................................................... 55 
4.2 E-PROM REPLACEMENT FOR THE STACK .......................................................................................... 55 
5 APPENDIX E: BOARD REPLACEMENTS....................................................................................................56 
5.1 OVERVIEW ........................................................................................................................................ 56 
5.2 STACK BOARD REPLACEMENT .......................................................................................................... 56 
5.3 MONITOR BOARD REPLACEMENT .................................................................................................... 56 
6 APPENDIX F: CHOPPER MOTOR /MIRROR REPLACEMENT ....................................................................57 
6.1 CHOPPER MOTOR / MIRROR REPLACEMENT ................................................................................... 57 
7 APPENDIX G: ZERO PIPE REPLACEMENT ................................................................................................60 
7.1 ZERO PIPE REPLACEMENT................................................................................................................. 60 
8 APPENDIX H: CROSS STACK ALIGNMENT ............................................................................................... 65 
8.1 CROSS STACK ALIGNMENT................................................................................................................ 65 
9 APPENDIX I: TROUBLE SHOOTING.......................................................................................................... 66 
10 APPENDIX J: PURGE FLOW GUIDELINES FOR PLANNING........................................................................67 
10.1 CALCULATORY FLOW TABLE FOR PIPELINING IN FACTORY ............................................................ 67 
11 APPENDIX K: SHORT CUT KEYES AND HIDDEN FUNCTIONS.................................................................... 68 
11.1 HIDDEN SHORTCUT KEYS ................................................................................................................ 68 
12 APPENDIX L: PARTS LISTS....................................................................................................................... 69 
13 APPENDIX M: DIGITAL /ANALOG POTENTIOMETER ADJUSTMENT ....................................................... 69 
13.1 DIGITAL / ANALOG OUTPUT ADJUSTMENT .................................................................................... 69 
14 APPENDIX O: SAFETY INFORMATION.....................................................................................................70 
14.1 WARNINGS AND CAUTIONS FOR OPERATION AND SERVICE .......................................................... 70 
14.2 U.S. REGULATIONS FOR THE USE OF LASERS .................................................................................. 70 
14.3 LASER-BASED OPACITY AND DUST MONITORING, SUBPART C....................................................... 71 
15 APPENDIX Q: WARRANTY ......................................................................................................................74 
15.1 WARRANTY TERMS AND CONDITIONS ........................................................................................... 74 
15.2 WARRANTY PROCEDURE ................................................................................................................ 75 
6MANUFACTURER´S CERTIFICATE OF CONFORMANCE TO EC-LABELLING PROCEDURE..............................76 
7CERTIFICATE OF ORIGIN ...........................................................................................................................77 

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

Page 3 / 105

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Business ID: 1627111-2

EU VAT ID: FI16271112

+358 10 3222 631

[email protected]

8DRAWINGS ..............................................................................................................................................78

8.1 EPA 3/SE OPTICAL DESIGN....................................................................................................................78

8.2 LM 3086 EPA3/SE LASER OPACITY AND DUST MONITOR.......................................................................79

8.3 OPTICAL BLOCK FOR LM3086 EPA3........................................................................................................ 80

8.4 OPTICAL BLOCK FOR LM 3086 SE ........................................................................................................... 81

8.5 LM3086 EPA3 LASER UNIT .....................................................................................................................82

8.6 LM3086 SE LASER UNIT.......................................................................................................................... 83

8.7 LM3086 EPA3/SE RECEIVER UNIT .......................................................................................................... 84

8.8 SUITABLE AUDIT FILTERS FOR AUDIT SLOT ............................................................................................ 85

8.9 AUDIT FILTER MOUNTING ORIENTATION AND BEST PRACTISES............................................................86

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

Page 4 / 105

WWW.MIP.FI

Aanitasomittarit.fi

Langatonmittaus.fi

Mikrofonit.fi

Opacitymonitors.fi

MIP Electronics Oy

Palokorvenkatu 2

04250 KERAVA, FINLAND

Business ID: 1627111-2

EU VAT ID: FI16271112

+358 10 3222 631

[email protected]

1MONITOR DESCRIPTION

1.1 INTRODUCTION

This manual describes the construction, operation, maintenance and features of the LM 3086 EPA3 and LM

3086 SE laser based opacity and dust monitors. These monitors are similar except the laser light source. EPA3

model uses He-Ne gas laser tubes and SE model uses semiconductor lasers. Further in the manual we use LM

3086 EPA3/SE to describe both models. The use of the laser light source brings many unique advantages that

set this monitor apart from the traditional state of the art design. A special effort has been spent to advance

the ease of use, maintenance, and conformance testing of the monitor. It should be noted that all sections

should be read carefully. Changing one mode of operation can often affect instrument performance and

possibly will change other modes to an undesirable state. Be sure you follow all the instructions and

understand what you are doing first. If you don’t understand, call for help.

1.1.1 BASIC DEFINITIONS

Opacity is defined as the property of the stack gases to attenuate visible light due to the presence of

particulate matter in the effluent. The amount of attenuation depends on the concentration of the light

absorbing or scattering particulate, and the length of the instrument path.

The basic definition of opacity requires that an instrument measures light intensity at the source (Io) and the

light intensity at the receiver (Ix) after it has passed through the stack effluent. The opacity is expressed as a

percent (Op%)

A fully transparent stack gas has opacity of 0%, and a fully opaque gas has opacity of 100%.

Opacity Op = ( 1- Ix / Io ) x 100 %

Optical Density: D = Log10 ( Io / Ix )

Detector

Channel

Light source

Receiver

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The Opacity can be compared with the attenuation of light and shows the percentage of absorbed light. The

Opacity measurement is used mostly in the USA and Asia. The advantage of Opacity is that the measuring

devices must not be calibrated.

The Extinction (optical density) runs linear to the dust load due to taking the logarithm:

Doubling the dust amount results in the display of the unit doubling. Extinction is used in European countries

and increasingly also in Asia. By calibrating the measuring location (not the measuring device) according to

VDI 2066 or EPA CFR 40 Part 60 #5, an exact display of the dust load in mg/m³ is achieved. The site depending

extinction coefficient k is defined by gravimetric comparative measurements. According to the smallest

quadratic error from at least 15 single measurements, the calibration curve is calculated for the measuring

location.

1.1.2 SINGLE PASS VS. DOUBLE PASS

Mann international regulations require a simulated zero and upscale calibration system to be included in the

monitor. This makes it necessary to modify the basic single-pass design. Most double-pass opacity and dust

monitors use a retro-reflector on the receiver side of the stack to reflect the light beam back to the

transceiver. In this case, the light source has passed through the stack effluent twice. An extra mirror is used

to simulate zero by inserting a mirror directly in front of the light source. This mirror swings down only when

in use, and swings away from the effluent when not in use. The mirror does have a potential for dirt

accumulation, which will in turn skew the true zero calibration.

The new laser technology of the LM3086 EPA3/SE relies on a single pass, dual path design. The single pass

refers to single crossing of the laser light across the stack through the effluent. The double path refers to the

second split laser light travelling through an independent fibre optic line (zero pipe) that passes around the

stack to the receiver. The second path is only possible since laser light sources possess monochromatic light

(one light wavelength) and highly collimated beams. This in turn allows a better more improved method of

auditing the opacity and dust monitor, since a zero reference value is constantly evaluated through the

independent light path through the fibre optic (zero pipe). The fibre optic or zero pipe has nothing to do with

fibre optic modem links used in stack to controller communications.

The following advantages are realized when using a single pass design as opposed to a double pass design:

1.1.2.1 Better Linearity

The detector in a double-pass design actually receives light through two processes:

1. Light that is returned from the receiver, or the retro-reflector in the case of a double pass system.

This light is attenuated by the stack particulate. The higher the concentration, the lower the intensity

of the light received.

2. Back scattered light from the stack particulate, which increases the opacity reading.

As the detected light intensity on a double pass system is the sum of the two passes of the light across the

stack, it is clear that the back-scattered light component will adversely influence linearity. All though this

effect is not severe in the low range, it may be significant in the higher end of the instrument range.

In contrast, the LM3086 EPA3/SE single pass laser design is free from back- scattered light.

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

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Business ID: 1627111-2

EU VAT ID: FI16271112

+358 10 3222 631

[email protected]

1.1.3 CHARACTERISTICS OF THE LIGHT SOURCE

The physical processes that influence an opacity and optical density reading depend on two things: properties

of the particulate (concentration, size distribution, light absorption characteristics) and the wavelength

distribution of the light source.

Any change in the particulate distribution will cause a change in the readings. However, any change in the

source wavelength will also cause a false readings unrelated to a change in emissions.

The laser source is a monochromatic light source radiating only one well- defined wavelength. In fact, laser

wavelengths are universally held constant to the extent that they are used to calibrate spectrophotometers,

which are used to analyze non-laser light sources.

Using non-laser light sources, the wavelength distribution changes with time. This problem is made even

more severe for the following reasons.

As the intensity of a non-laser light source diminishes over time, the amplitude or intensity can be increased.

The wavelength distribution however cannot be changed, as it invariably does over time.

With a monochromatic light source like the laser, the intensity does degrade, but is compensated for

electronically. The wavelength however does not fluctuate with intensity drops.

1.1.4 CHARACTERISTICS OF THE BEAM GEOMETRY

In order to minimize the effects of stray or scattered light sources the opacity and dust monitor should have a

spatial response that is very directional, i.e. contained in the smallest possible space through the monitoring

path.

The geometrical response of the opacity volume is the volume of space that is bound by the angle of view

and the angle of projection. This is simple terms, refers to the opacity sampling cross section. Particulate

within this volume only will contribute to the opacity reading. In most non-laser opacity and dust monitors

with well-designed collimation optics, the angles are in the order of 2º to 4º.

The laser light source has an extremely well collimated beam. The angle of projection is expressed as the

divergence of the beam. In the laser opacity unit, the divergence is 0.04º. This extremely high level of

collimation also defines the total spatial response of the laser opacity and dust monitor (virtually

independently of the angle of view) making the alignment very easy and allowing for very long monitoring

path lengths. This makes the laser opacity and dust monitor not path length dependent.

1.1.5 CHARACTERISTICS OF THE LIGHT RECEIVER

Using non-laser light sources, the diameter of the light beam at the receiver is larger than the active area of

the detector. This is called an overfill system.

The laser beam in a laser opacity and dust monitor is fairly small even over extended distances. The initial

beam size is about 1 mm, growing approximately 0.8 mm for each meter of the monitoring path-length.

Consequently, the beam diameter is about 5 mm at 5 meters’ distance and 9 mm when 10 meters apart from

the light source. The beam fits well within the 100 mm active area of the detector, allowing for small

alignment changes due to vibration or heat fluctuations. As the detector now contains all of the laser beam

within its active detector surface, this unique system is called the under-fill system leading to two immediate

improvements from the overfill systems in non-laser opacity and dust monitors.

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

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04250 KERAVA, FINLAND

Business ID: 1627111-2

EU VAT ID: FI16271112

+358 10 3222 631

[email protected]

1. The clear path response (zero) of the under-fill system is independent of the path-length as the total

laser beam is confined inside the detector at any distance. In the overfill system, the amount of light

intensity decreases as the path-length grows. This means that the over-fill system must be zeroed for

each application and may require different hardware for different distances. The laser under-fill

system does not have an application dependent zero state and is portable to other applications with

different path-lengths.

2. The response of the under-fill system is more uniform and more tolerant to cross stack alignment.

Small changes in the alignment due to temperature variations or vibrations are normally unavoidable

in stack emissions monitoring. With the under-fill system, any small deviations in cross-stack

alignment are not as critical as in the overfill system. In the under-fill system, alignment changes are

controlled by the size of the laser beam, and the oversized detector. As the laser beam moves due to

alignment shifts, the large detector having a large active surface, contains the laser beam within its

detector area. The detector is manufactured using a time-proven semiconductor process

guaranteeing uniform sensitivity across the entire surface (< 1 % deviation). No non-laser-based

opacity and dust monitor can make this guarantee. Of course, drastic shifts in alignment will affect

monitoring reliability when the laser beam shifts outside the detector area. High vibrations and

temperature shifts should be controlled as best as possible since they will affect the accuracy of the

reading, and the life-span of the monitor. All of these factors make the under-fill system superior to

the overfill system.

1.1.6 MAINTENANCE AND AUDIT PROCEDURE ADVANTAGES

Note: All screws and hex bolts are metric except for the laser 90ºdeflector hold-down bolts (4-40 UNC;

3/32”).

The big advantage of using the laser is that a minimum amount of optics, are needed in a normal monitoring

path. Because of the excellent collimation characteristic of the laser light sources, no collimation lenses are

used. In addition, since a dual-path exists using the zero pipes no retro-reflectors are needed. In fact, after

the small 90º turning mirror on the laser tube, there are no optical surfaces in the measurement path until

the laser beam reaches the receiver lens.

In the laser-based opacity and dust monitor, the only optical surfaces that are likely to accumulate dust are

those in the receiver. This includes the receiver lens, the zero pipe lens, and the two sides of the zero pipe

mirror. Opening can clean all three of which, the swing hinge held by four hex bolts (5 mm) on the receiver

side. The zero pipe mirror can be loosened with a 1.5 mm hex key. This amount of contamination is

constantly measured and compensated for during the zero cycle. Very rarely, the detector surface may need

cleaned. Before opening the hasp side exposing the detector, put the transmitter in audit mode. Sometimes

excessive light on the detector may overload the detector, causing the software to inaccurately report

opacity readings. DO NOT use any solvents to clean the detector, it will be damaged. Since the detector is

isolated from stack gases, it is rather unlikely that this will need to be cleaned, however, it should be checked

periodically. There is no need to remove the laser, transmitter, or the receiver for cleaning. There exists one

other optical surface, which should only be cleaned if a calibration problem occurs. Inside the optical block

(see drawings at end of this manual), there is a chopper mirror. While a blower protects this chopper mirror,

it is possible to get some dirt on the mirror. See the troubleshooting for help in diagnosing calibration

problems, and the appendices for cleaning procedures and guidelines.

MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018

Page 8 / 105

WWW.MIP.FI

Aanitasomittarit.fi

Langatonmittaus.fi

Mikrofonit.fi

Opacitymonitors.fi

MIP Electronics Oy

Palokorvenkatu 2

04250 KERAVA, FINLAND

Business ID: 1627111-2

EU VAT ID: FI16271112

+358 10 3222 631

[email protected]

1.1.7 SUMMARY OF LASER BASED OPACITY BENEFITS

The same ease of use extends to audit procedures. To conduct an audit, there is no need to remove either

component of the monitor, nor use any audit jigs. The zero pipe serves as an effluent-free audit path. Audit

procedures will be discussed later.

The following is a brief summary of the benefits of using a laser-based opacity and dust monitor instead of a

non-laser opacity and dust monitor.

Technical Features

Laser Opacity Improvements

Dual path, single pass design with optical fibre (zero

pipe) reference path

Better Linearity over whole range

No audit jig required

Laser Source and Beam Quality

Ultimate in wavelength stability

100 % better beam collimation

Easier to align

Long path-lengths possible

Under-Fill System

Zero is independent of path-length

More uniform response to alignment changes from

heat and vibration due to large homogenous

detector

Maintenance and other Features

Minimum optics means less window dirt

1.2 MONITOR PARTS DESCRIPTION

The LM3086EPA SE monitor consists of three components:

1. Laser (Transmitter) Unit L3086EPA3 (includes laser)

2. Receiver Unit R3086EPA3 (includes conduit with zero pipe and signal wire)

3. Controller Unit M3086EPA3 (includes serial connections)

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