MIP LM 3086 EPA3 Operation manual
MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018
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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
m
IP
MIP LM 3086 SE/EPA3 manual, rev2 –16.10.2018
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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:
Palokorvenkatu 2 Technical: support@mip.fi
04251 Kerava
Finland
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Table of content
1MONITOR DESCRIPTION ........................................................................................................................... 4
1.1 INTRODUCTION ....................................................................................................................................... 4
1.1.1 BASIC DEFINITIONS ............................................................................................................................. 4
1.1.2 SINGLE PASS VS. DOUBLE PASS........................................................................................................... 5
1.1.3 CHARACTERISTICS OF THE LIGHT SOURCE .......................................................................................... 6
1.1.4 CHARACTERISTICS OF THE BEAM GEOMETRY .................................................................................... 6
1.1.5 CHARACTERISTICS OF THE LIGHT RECEIVER........................................................................................ 6
1.1.6 MAINTENANCE AND AUDIT PROCEDURE ADVANTAGES .................................................................... 7
1.1.7 SUMMARY OF LASER BASED OPACITY BENEFITS ................................................................................ 8
1.2 MONITOR PARTS DESCRIPTION ............................................................................................................... 8
1.2.1 LASER UNIT LM3086 EPA3 .................................................................................................................. 9
1.2.2 LASER UNIT LM3086 SE..................................................................................................................... 11
1.2.3 RECEIVER UNIT R 3086EPA3/SE ........................................................................................................ 13
1.2.4 CONTROLLER UNIT M3086EPA3/SE.................................................................................................. 14
1.3 SYSTEM INTERCONNECTIONS................................................................................................................14
1.4 MONITOR SPECIFICATIONS....................................................................................................................14
1.4.1 LASER (TRANSMITTER) UNIT SPECIFICATION.................................................................................... 15
1.4.2 RECEIVER UNIT SPECIFIC SPECIFICATIONS ........................................................................................ 15
1.4.3 CONTROLLER UNIT SPECIFICATIONS................................................................................................. 15
1.4.4 CONTROLLER RESOLUTION ............................................................................................................... 16
1.4.5 POWER REQUIREMENTS................................................................................................................... 16
1.4.6 OPERATION ENVIRONMENT ............................................................................................................. 16
2MONITOR DISPLAYS AND CONTROLS.......................................................................................................16
2.1 LASER UNIT CONTROLS..........................................................................................................................16
2.1.1 RECEIVER UNIT CONTROLS ............................................................................................................... 17
2.1.2 CONTROLLER UNIT DISPLAYS AND CONTROLS ................................................................................. 17
2.1.3 AUTOMATIC SHUTTER GATE............................................................................................................. 17
2.2 MONITOR MODES OF OPERATION ........................................................................................................17
2.2.1 CONTROLLER DIAGNOSTIC MODES .................................................................................................. 18
2.2.2 RUN-TIME DIAGNOSTICS .................................................................................................................. 19
2.2.3 MAIN MONITORING MODE .............................................................................................................. 20
2.2.4 AUTO ZERO MODE............................................................................................................................ 20
2.2.5 AUTO SPAN MODE............................................................................................................................ 21
2.2.6 SERVICE MODES................................................................................................................................ 26
2.2.7 ADDITIONAL SUB MENUS FROM DYNAMIC MODE .......................................................................... 33
3INSTALLATION AND START-UP.................................................................................................................35
3.1 PRE-INSTALLATION TESTS...................................................................................................................... 35
3.2 INSTALLATION SITE REQUIREMENTS ..................................................................................................... 35
3.2.1 TURBULENCE AND EFFLUENT MIXING.............................................................................................. 35
3.2.2 PRESSURE CONSIDERATIONS............................................................................................................ 35
3.2.3 VIBRATION AND ALIGNMENT ........................................................................................................... 36
3.2.4 TEMPERATURE AND MOISTURE ....................................................................................................... 36
3.3 CROSS-STACK ALIGNMENT CHECK......................................................................................................... 36
3.4 CALIBRATION/LINEARITY CHECK............................................................................................................37
3.5 EPA FIELD CERTIFICATION TESTS DURING START-UP.............................................................................37
4MAINTENANCE AND SERVICE...................................................................................................................38
4.1 SELF-DIAGNOSTIC TEST..........................................................................................................................38
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4.2 DIRT ACCUMULATION TEST ................................................................................................................... 38
4.2.1 CLEANING THE OPTICS...................................................................................................................... 38
4.3 CROSS-STACK ALIGNMENT CHECKS.......................................................................................................39
4.4 HARDWARE DIAGNOSTICS IN THE LASER UNIT......................................................................................40
4.5 INSTALLATION INSTRUCTIONS............................................................................................................... 40
5APPENDIXES.............................................................................................................................................41
5.1 APPENDIX A: ROUTINE MAINTENANCE..................................................................................................41
5.1.1 OVERVIEW ........................................................................................................................................ 41
5.1.2 DAILY CHECKS ................................................................................................................................... 42
5.1.3 PERIODIC CHECKS ............................................................................................................................. 42
5.1.4 IRREGULAR CHECKS .......................................................................................................................... 42
5.2 APPENDIX B: CLEANING THE OPTICS...................................................................................................... 43
5.2.1 OVERVIEW ........................................................................................................................................ 43
5.2.2 RECEIVER SIDE / CLEANING A DIRTY WINDOW ................................................................................ 43
5.2.3 TRANSMITTER SIDE........................................................................................................................... 47
5.3 APPENDIX C: LASER UNIT REPLACEMENT AND ALIGNMENT PROCEDURES ...........................................49
5.3.1 OVERVIEW ........................................................................................................................................ 49
5.3.2 REPLACEMENT LM 3086EPA3........................................................................................................... 49
5.3.3 REPLACEMENT LM 3086SE ............................................................................................................... 52
5.3.4 ALIGNMENT ...................................................................................................................................... 53
5.3.5 CLEAR STACK PROCEDURE ................................................................................................................ 54
5.4 APPENDIX D: E-PROM REPLACEMENT ...................................................................................................55
5.4.1 E-PROM REPLACEMENT FOR THE MONITOR UNIT ........................................................................... 55
5.4.2 E-PROM REPLACEMENT FOR THE STACK .......................................................................................... 55
5.5 APPENDIX E: BOARD REPLACEMENTS....................................................................................................56
5.5.1 OVERVIEW ........................................................................................................................................ 56
5.5.2 STACK BOARD REPLACEMENT .......................................................................................................... 56
5.5.3 MONITOR BOARD REPLACEMENT .................................................................................................... 56
5.6 APPENDIX F: CHOPPER MOTOR /MIRROR REPLACEMENT ....................................................................57
5.6.1 CHOPPER MOTOR / MIRROR REPLACEMENT ................................................................................... 57
5.7 APPENDIX G: ZERO PIPE REPLACEMENT ................................................................................................60
5.7.1 ZERO PIPE REPLACEMENT................................................................................................................. 60
5.8 APPENDIX H: CROSS STACK ALIGNMENT ............................................................................................... 65
5.8.1 CROSS STACK ALIGNMENT................................................................................................................ 65
5.9 APPENDIX I: TROUBLE SHOOTING.......................................................................................................... 66
5.10 APPENDIX J: PURGE FLOW GUIDELINES FOR PLANNING........................................................................67
5.10.1 CALCULATORY FLOW TABLE FOR PIPELINING IN FACTORY ............................................................ 67
5.11 APPENDIX K: SHORT CUT KEYES AND HIDDEN FUNCTIONS.................................................................... 68
5.11.1 HIDDEN SHORTCUT KEYS ................................................................................................................ 68
5.12 APPENDIX L: PARTS LISTS....................................................................................................................... 69
5.13 APPENDIX M: DIGITAL /ANALOG POTENTIOMETER ADJUSTMENT ....................................................... 69
5.13.1 DIGITAL / ANALOG OUTPUT ADJUSTMENT .................................................................................... 69
5.14 APPENDIX O: SAFETY INFORMATION.....................................................................................................70
5.14.1 WARNINGS AND CAUTIONS FOR OPERATION AND SERVICE .......................................................... 70
5.14.2 U.S. REGULATIONS FOR THE USE OF LASERS .................................................................................. 70
5.14.3 LASER-BASED OPACITY AND DUST MONITORING, SUBPART C....................................................... 71
5.15 APPENDIX Q: WARRANTY ......................................................................................................................74
5.15.1 WARRANTY TERMS AND CONDITIONS ........................................................................................... 74
5.15.2 WARRANTY PROCEDURE ................................................................................................................ 75
6MANUFACTURER´S CERTIFICATE OF CONFORMANCE TO EC-LABELLING PROCEDURE..............................76
7CERTIFICATE OF ORIGIN ...........................................................................................................................77
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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
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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 )
S
Detector
Channel
Light source
I0
Ix
E0
Ex
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.
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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.
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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.
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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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1.2.1 LASER UNIT LM3086 EPA3
The laser unit consists of the following parts:
1. A hinged fibre-glass NEMA 12 X rated enclosure attached to a hinged, standard 4" ANSI 150 # flange.
2. ½ inch penetration for instrument air connection.
3. System components are assembled for ease of service and access.
4. Green, low power semiconductor laser and associated power supply. Laser is mounted on the front
optical block.
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5. Fibre optic (zero pipe) for zero reference between transmitter and receiver units.
6. Optical block containing a chopper (sometimes called Dopper) motor with a four-sided mirror. Mirror
includes an upscale filter, and three deflecting mirrors to divert light source to the zero pipe, and to
the reference detector.
7. Processor circuit board for controlling the optical block and calculating opacity values. All on-stack
calculated opacity values are sent through the serial link (RS 422 for serial cable, RS 232 if using a
fibre optic modem) in digital form, eliminating current losses.
8. Power circuit board with status lights, supplying regulated voltages to the processor board and the
chopper motor.
9. Terminal blocks for wire connections
10. Local power switch
11. Audit filter slot for use while conducting audit procedures.
12. An optional fibre optic modem for communication between the controller and transmitter units.
13. Stainless steel fail-safe shutter assembly. Closes on loss of purge air and indicates a purge fault on the
controller.
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1.2.2 LASER UNIT LM3086 SE
The laser unit consists of the following parts:
1. Fibre optic (zero pipe) for zero reference between transmitter and receiver units
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2. Reference Detector.
3. Cable Link to Processor Board
4. Power circuit board with status lights, supplying regulated voltages to the processor board and the
chopper motor
5. Processor circuit board for controlling the optical block and calculating opacity values. All on-stack
calculated opacity values are sent through the serial link (RS 422 for serial cable, RS 232 if using a
fibre optic modem) in digital form, eliminating current losses.
6. Complete Zero Pipe: Protective tube “Anaconda” with Fiber and Cable.
7. Optical block containing a chopper (sometimes called Dopper) motor with a four-sided mirror. Mirror
includes an upscale filter, and three deflecting mirrors to divert light source to the zero pipe, and to
the reference detector.
8. Local power switch.
9. A hinged fibre-glass NEMA 12 X rated enclosure attached to a hinged, standard 4" ANSI 150 # flange.
10. Audit filter slot for use while conducting audit procedures.
11. A G11/4” to 38mm(ID) connection for purge air (G11/4” to 19mm(ID) optional).
An optional hand-held unit is available for servicing, trouble shooting, and auditing the unit more easily,
allowing for easier service without watching the main controller unit. One person if necessary can do Service
and audits.
Refer to the appendix of this manual for the location of the different components of the laser unit including
terminal block connections.
The laser unit L3086 has three modes of operation:
Normal Mode –The laser beam passes through the stack effluent to the main detector located in the
receiver. The main detector signal is returned to the stack processor board, and compared to the reference
detector signal. The opacity measurement is synchronized to the rotation of the chopper wheel to reject any
stray non-laser light.
Simulated Zero Mode –(Zero and Dirty Window check) the laser beam is constantly deflected through the
effluent-free zero pipe checking for dirt contamination on any of the three optical surfaces on the receiver
unit.
Calibration Mode –(Span Check) the upscale filter located on one side of the chopper mirror is included in
the zero measurement loop. The value of the filter is measured and the corresponding value is stored in
memory.
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1.2.3 RECEIVER UNIT R 3086EPA3/SE
The receiver consists of the following:
1. A hinged anodized aluminium water tight enclosure attached to a hinged standard 4 inch ANSI 150 #
flange. Bolthole patterns are included in the drawings section.
2. A G1 ¼” (38mm ID) connection for purge air. Optional G1 ¼” (19mm ID) connection available.
3. Large area lens accessible from the hinged, square flange of the receiver. The main detector is
accessible from the hasp side of the receiver.
4. A zero pipe ferrule holder with a beam deflector mirror to orient the laser beam to the main
detector.
5. A connector for signal connections to the transmitter.
6. A large 100mm focusing lens to capture the laser beam and direct it onto the main detector.
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1.2.4 CONTROLLER UNIT M3086EPA3/SE
The controller unit contains all the electronics necessary to calculate opacity corrections (window
compensation and stack exit correction {also known as stack taper ratio}) and averaged opacity values. The
controller performs alarm limits and operation checks, memory functions and helpful special operations as
well. The controller also provides a series of terminal connections to monitor system status via a DCS or
process control panel.
The controller is housed in a standard 19-inch rack mountable frame. Power to the controller unit is supplied
by an standard power plug, provided with the unit. The controller also has an incorporated serial link for
communications with the transmitter. Serial cable lengths should be kept below 600 m lengths. If this is not
possible, the optional fibre optic modem can operate at a maximum of 3000-meter distances. Local MIP
dealer must install the optional fibre optic modem on request.
1.3 SYSTEM INTERCONNECTIONS
For the electrical and optical connections between different components, see the drawings section ( number
6 ) of this manual.
1.4 MONITOR SPECIFICATIONS
The following specifications of the LM 3086 EPA3/SE monitor describe its technical features and performance
specifications. It should be understood that the installation environment will ultimately affect the
performance of the complete instrument.
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
m
IP
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1.4.1 LASER (TRANSMITTER) UNIT SPECIFICATION
EPA3
RedEPA3
SE
Wavelength
543 nm
632.8nm
655nm
Laser output power
0.8 –1.8mW
1 –5mW
0.5 –1.5mW
Beam diameter
0.75 mm
0.6 mm
2.5 mm
Beam Divergence (AOP)
4 mrad
1.4 mrad
0.4 mrad
Warm-up Time:
1 hour
Operating Temperature:
-28°C to 68°C /-18°F to 154°F
Operating Humidity:
0 –90 % RH
Mounting Flanges:
4 inch 150 # ANSI flange
Power Supply:
115 or 230 VAC 40 VA
Angular Response:
< 0.06°
Background Sensitivity:
<0.2 % Opacity
Back Scatter Opacity Contribution:
<0.2 % Opacity
Calibration Error:
<0.5 % Opacity
Purge Flow:
See appendix for requirements
1.4.2 RECEIVER UNIT SPECIFIC SPECIFICATIONS
Detector
Optically matched silicon detector 20mm in
diameter with a large 100 mm focusing lens
Angle of View:
< 2.0°
Operating Temperature:
-28°C to 68°C /-18°F to 154°F
Operating Humidity:
0 –90 % RH
Mounting Flanges:
4 inch, 150 # ANSI, see drawings for bolt hole
patterns.
Purge Flow:
See appendix for requirements
1.4.3 CONTROLLER UNIT SPECIFICATIONS
Operating Range:
0 –99.9 % opacity.
Span Range
10 % - 99 % with 1 % increments.
Automatic Calibration Sequence
1 –99 hours with 1 hour increments
Timing Options:
Hourly/or by minutes based on internal
clock or internal clock time or externally
by a contact closure.
Zero/Span Cycle Time
1 –99 seconds with 1 second increments,
Opacity Averaging:
1 –99 minutes with 1 minute increments.
(EPA requires 6 minute block averages).
Stack Exit Correction (SEC):
0.20 –2.50 with 0.01 increments.
(Stack Taper Ratio)
(Password protected)
Operating Humidity:
0 –90 % RH
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1.4.4 CONTROLLER RESOLUTION
Opacity:
0.1 %Opacity
Optical Density:
0.001 OD
Particulate Concentration:
0.001 grains/ft 3 or 1 mg/m3
1.4.5 POWER REQUIREMENTS
Laser (Transmitter) Unit:
115 or 230 VAC, 40 VA
Control Unit:
100…250 VAC, 15 VA
Optional Blowers:
3400VAC, 1000 VA or 2* 230VAC, 600VA
1.4.6 OPERATION ENVIRONMENT
Laser/Transmitter Ambient Temperature
Limits:
- 29°C to 49°C/-20°F to 120°F
2MONITOR DISPLAYS AND CONTROLS
2.1 LASER UNIT CONTROLS
All controls of the laser unit are located inside the enclosure. The controls consist of four simple items:
•A power switch
•A fuse for protecting the electronics
•Shutter gate position selector
•Push button audit switch
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2.1.1 RECEIVER UNIT CONTROLS
There are no electrical controls in the receiver unit.
2.1.2 CONTROLLER UNIT DISPLAYS AND CONTROLS
The D/A converter inside the controller can be adjusted to accommodate signal loss due to wire lengths and
impedance of PLC units, or DCS devices. There are four potentiometers inside the controller, none with
labels. They sit on the main board where the E-Prom fits, all lined up, with the adjustment screw on top. The
screws are painted shut since they are calibrated at the factory. Since it is impossible to set each pot to the
customer’s system they may need to be adjusted if the LCD display does not agree with the data collection
device.
See the appendices for a complete procedure on how to adjust the analogue outputs. On the controller,
there are three features of the controller. The first is the two-line alphanumeric display, which displays the
opacity readings, averages, text for mode selections, and fault descriptions. The second component is the
push buttons. Each push button, and some combinations of the push buttons activate certain menus and
functions. The details of each push button and their functions will be described in detail later. Thirdly, there
are a series of trouble lights, the functions of which are explained by either the printing on the controller
plate, or their physical association with certain push buttons.
2.1.3 AUTOMATIC SHUTTER GATE
The automatic shutter gate closes upon loss of purge air (< 1 mig), therefore protecting all internal
components of the transmitter enclosure from flue gases. The shutter gate will also close if the door is
opened. If the shutter does not close when the door is opened, check the position of the shutter gate
selector. Severe damage may occur when exposing the monitor to flue gases. The shutter gate can be kept
open manually for inspection and service by moving the shutter gate selector to the “open” position. Do not
keep the shutter in the manually open position without the purge air diverted to the stack when the monitor
is exposed to flue gas. If the shutter closes due to a loss of purge air two things will happen. The controller
will receive a purge fail alarm, and the opacity reading will spike to 99.9 %. The transmitter is included with a
½ inch hole to receive A fitting for customer supplied purge air. If the blower option is purchased, a bulkhead
will install at the factory
2.2 MONITOR MODES OF OPERATION
Modes are presented in the following order:
1. The diagnostic and operational modes are presented in the order in which they appear.
2. The manual modes, which are likely to be operated occasionally.
3. The set-up modes, which are used to configure the system to meet the customer’s needs.
4. The service modes in order of occurrence for use by specialized personnel.
For each mode, all the entry and exit conditions as well as its influence on the monitors operation are
explained. Most mode operations are explained by the display.
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2.2.1 CONTROLLER DIAGNOSTIC MODES
This mode is entered every time the controller powers up, or when a controller reset is performed by pushing
the up, down, and next buttons simultaneously for > 5 seconds.
The diagnostic mode begins by displaying text first for about 3 seconds. At the same time, all indicator lights
are turned on; relay outputs close (or open depending on relay logic), and the analogue out channels will
show 4mA for about 1 second, and 20 mA for 1 second. The current loop test can be reproduced and
adjusted from the hardware test mode described later. After these tests, the unit will run through the
following self-diagnostic procedure checking various modes.
*Diagnostics flow as presented *Answerback displays to the tests
by tests and LCD-displays If a test fails then “OK!”-string is replaced by “FAIL”.
All the tests happen fully automatically without user interference. To repeat a test keep Up-key pressed,
while the test is active. To skip the remaining tests, push Down-arrow
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