Opsis LD500 Operation manual

Opsis LD500 CEM System
Emitter and Receiver Units
ER060L, ER060AUTOL
Installation & User´s Guide
Release 1

Copyright © Opsis AB, Furulund, April 2006. Release 1.
Copyright
© Opsis AB. All rights reserved. This manual and the product described in it are copyrighted with
all rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in
a retrieval system or translated into any language in any form by any means without the written per-
mission of Opsis AB. Information in this document is subject to change without notice.
Trademarks
OPSIS is a trademark owned by Opsis AB, Sweden. Other brands and product names are trademarks
or registered trademarks of their respective companies. Companies, names, and data used in exam-
ples herein are fictious unless otherwise noted.
Limited warranty
The warranty conditions of this product are described in the purchase agreement between the buyer
and the seller. However, a condition for any warranty is that the product is installed, operated and
maintained in accordance with the specifications and instructions issued by Opsis AB including but
not limited to this manual. This warranty is limited to replacement of defective material or documen-
tation supplied by Opsis AB and in no event shall Opsis AB or its suppliers be liable for any loss of
profit or any other commercial damage, including but not limited to direct or indirect, special, inci-
dental, contingent or consequential damages resulting from any defects on the product or its docu-
mentation including damages from downtime, loss of goodwill, damage to or replacement of
equipment or property.
Contact information
Adress Opsis AB
Box 244
SE-244 02 Furulund, Sweden
Telephone [phone]
Fax [phone]
Web-site http://www.opsis.se
E-mail [e-mail]

Contents
1 Emitters and receivers ................................................................................. 1
1.1 The ER060L system ...................................................................................... 1
1.1.1 Technical specifications ................................................................................. 1
1.1.2 The emitter EM060L ..................................................................................... 2
1.1.3 The receiver RE060L ..................................................................................... 3
1.2 The ER060AUTOL system ........................................................................... 4
1.2.1 Technical specifications ................................................................................. 5
1.2.2 The receiver RE060AUTOL .......................................................................... 5
1.2.3 The calibration cell ........................................................................................ 5
1.3 Stack port connections - port installation kit ................................................. 6
2 LD500 CEM system accessories ................................................................. 7
2.1 The PM101L power supply ........................................................................... 7
2.2 The PW061 purge air cassette ....................................................................... 7
2.3 The optical fibres ........................................................................................... 8
3 CU004/007 Calibration unit ...................................................................... 11
3.1 Specifications ............................................................................................... 13
3.2 The control unit ............................................................................................ 13
3.3 Cables .......................................................................................................... 14
4 Safety precautions ...................................................................................... 17
4.1 Precautionary measures ............................................................................... 17
4.2 CU004/CU007 ............................................................................................. 18
5 Installation .................................................................................................. 19
5.1 Placement conditions for the emitter/receiver ............................................. 19
5.2 Placement conditions for the analyser ......................................................... 20
5.3 Flanges and PW061 cassettes ...................................................................... 20
5.4 Installation of ER060L ................................................................................ 21
5.5 Installation of ER060AUTOL ..................................................................... 21
5.5.1 Electrical connections .................................................................................. 22
5.5.2 Fiber optic connections ................................................................................ 22
6 Light adjustment kit LA060 ..................................................................... 23
6.1 Visually alignment of the transmitter and receiver with the LA060 ........... 24
6.2 Alignment of the transmitter and receiver with the LA060 with feedback
from the LD500 ........................................................................................... 24
6.3 Measure light throughput to ensure status of fibre or light transmitter
(version 1.2 and up) ..................................................................................... 25
6.4 Spare parts ................................................................................................... 25
7 Multiplexers and demultiplexers .............................................................. 27
7.1 Splitting multiplexers and demultiplexers ................................................... 27
7.1.1 Splitting multiplexers, MX10nL .................................................................. 28

7.1.2 Demultiplexers, MXn01L .............................................................................28
7.2 Switching multiplexers, SX10nL .................................................................28
7.2.1 Technical specification .................................................................................29
7.2.2 The DIP switches ..........................................................................................29
7.2.3 RS232 port configuration .............................................................................30
7.2.4 Software configuration .................................................................................30
7.2.5 Function test of the switch ............................................................................31
7.2.5.1 The function LED´s ......................................................................................31
8 Maintenance ................................................................................................33
8.1 Check list for preventive maintenance .........................................................33
8.2 Emitter and receiver .....................................................................................34
8.2.1 Cleaning the mirrors and windows ...............................................................34
8.3 Autocalibration units ....................................................................................34
9 Installation drawings ..................................................................................35
A Appendix: ER060AUTOL setup ..................................................................i
A.1 Enter the IO256 software .................................................................................i
A.2 Communication units using the IOMan protocol ............................................i
A.3 Load the settings from the IOMan modules ...................................................ii
A.4 Logg the calibration cell temperature .............................................................ii
A.5 Configuration of the CU007 ...........................................................................ii

1
Emitters and receivers 1
1.1 The ER060L system
The ER060L system consists of an emitter EM060L and a receiver RE060L. A power sup-
ply unit PM101L is needed to power the electronics in the receiver.
1.1.1 Technical specifications
ER060L system EM060L/RE060L
Dimensions (L ×W × H) 385 × 200 × 115 mm
Material aluminium/stainless steel
Weight (approx.) 7 kg
Window material quartz
diameter 50 mm
Mirror material quartz substrate
Ambient temperature -20 °C to +45 °C
Degree of protection IP54
Mounting 1 1/2” internally threaded pipe socket
Monitoring path length (recommended) 0.5 to 5 m
Purge air connections 6 mm
Note: If the ambient temperature is exceeding +45 °C it is necessary to cool the elec-
tronics in the receiver, e.g. by purging air through the receiver. The air should be clean
and free from oil and dust.
F
igure 1.1. The ER060L system.

Emitters and receivers
2
1.1.2 The emitter EM060L
The EM060L can transmit light over a path length of up to 5 meters. The light is led from
the laser head unit to the emitter via an optical fiber. The ending of the fiber is placed at
the focal point of a parabolic mirror. The light emitted by the transmitter is thus almost
parallel.
Main parts of the emitter EM060L
1 1 ½“ thread
2 Purged air inlet
3 Optical fibre inlet
4 Optical fibre
5 Mirror
Note: The coating on the mirror is very sensitive. It must not be touched or cleaned with
liquids.
F
igure 1.2. The emitter EM060L.
1
2
3
45

Emitters and receivers
3
1.1.3 The receiver RE060L
The RE060L unit contains a fibre holder and a mirror. The optical components are adjust-
able for the optimisation of the calibration light.
Main parts of the receiver RE060L
1 1 ½“ thread
2 Purged air inlet
3 Optical fibre inlet
4 Power inlet (±12 V)
5Detector
6Mirror
7 A/D converter
Note: The coating on the mirror is very sensitive. It must not be touched or cleaned with
liquids.
F
igure 1.3. The receiver RE060L.
1
2
34
56
7

Emitters and receivers
4
1.2 The ER060AUTOL system
ER060AUTOL is designed to be used for flue gas monitoring in stacks/ducts in combina-
tion with one Opsis LD500 analyzer. The ER060AUTOL consists of one emitter, EM060L
and one receiver RE060AUTOL.
In addition to a cross stack optical monitoring path, the ER060AUTOL provides automatic
calibration function. For fully automated calibration, a calibration unit CU007, must be
used in combination with the analyser and the ER060AUTOL.
The emitter and the receiver are units are mounted on purge air cassettes, PW061. The
PW061 is screwed on 1 1/2” pipe sockets. Port connections on stack are designed for 4”
ANSI flanges.
F
igure 1.4. The ER060AUTOL system designed for fully automated calibration.
LD500
Laser diode gas analyser
RE060AUTOL
receiver
EM060L
emitter
PM101L
power
supply
Fibre optic cable
Communication
cable
Calibration
cell
Fibre collimator
Calibration
gas
Mirror
Cell temperature
Calibration on/of
f
IOMan
Multiplexer
Calibration
unit
Detector

Emitters and receivers
5
1.2.1 Technical specifications
1.2.2 The receiver RE060AUTOL
The receiver is equipped with one parabolic mirror. The mirror collects and focus the re-
ceived light on to the detector, which is located at the focal point of the mirror. The light
will pass through a calibration cell on its way to the detector.
The light from the calibration lamp is focus in to a separate parabolic mirror. From the par-
abolic mirror the light is projected in two mirrors. After the second 45° angle mirror,
which is movable, the light enters the “normal “ path and is collected and focused in to the
optical fiber.
During a calibration the movable 45° angle mirror moves out and blocks the light from the
measurement path. By doing so, light from the calibration path will be collected in to the
optical fiber.
1.2.3 The calibration cell
The calibration cell mounted in the receiver makes it possible to perform not only zero
point calibrations, but automatic multi-point span calibrations for all gases being moni-
tored. The computer software supports up to three different calibration concentrations for
each gas and when connected via a CU007 auto-calibration unit, the calibrations are fully
automatic.
The inner diameter of the cell is 2” (53 mm) and the length is approximately 130mm. The
temperature controller, TC100, is located on the control unit.
The optical fiber is leading the captured light to the Opsis analyser unit, which by those
means can be protected from high temperature, dust, humidity etc.
ER060AUTOL system RE060AUTOL
Dimensions (L ×W × H) 720 × 310 × 330 mm
Material aluminium/stainless steel
Weight (approx.) 23 kg
Window material quartz
diameter 50 mm
Mirror material quartz substrate
Ambient temperature -20 °C to +45 °C
Degree of protection IP54
Mounting 1 1/2” internally threaded pipe socket
Monitoring path length (recommended) 0.5 to 5 m
Purge air connections 6 mm
Mirror voltage supply 230 VAC/115 VAC

Emitters and receivers
6
1.3 Stack port connections - port
installation kit
ER060AUTOL is a cross stack monitoring unit. Emitter and receiver are mounted on op-
posite sides, on 1 1/2” pipe socket connections. The recommended mount is a port kit sup-
plied by Opsis which includes set of 4” ANSI flanges that are attached to the stack/duct
walls.
In order to maximize system performance, it is critical that the flanges are properly
aligned. Proper alignment can be achieved by first installing the flange kit on one side, and
then by using the pipe insert for alignment of a long stick/ pipe inserted through the stack,
the exact aligned location for the second port can be found.
The pipe insert that extends in to the flue gas reduces turbulent effects on the monitoring
path length. The exact length of the pipe insert should be determined for each specific ap-
plication. As a guideline, the minimum length of the pipe insert is 1 ft, and the maximum 5
ft.
In raw gas application, i.e. before ESP / bag house particulate removals, it is recommended
that the total monitoring path length for the ER060AUTOL does not exceed 5.5 m or 18 ft.
F
igure 1.5. The receiver RE060AUTOL, side view.