SIGRIST StackGuard 2 User manual

INSTRUCTION MANUAL
StackGuard 2 SYSTEM
SIGRIST
Dust Emissions Measuring System
SIGRIST-PHOTOMETER AG
Hofurlistrasse 1
CH-6373 Ennetbürgen
Switzerland
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet: www.photometer.com
Document No.: 10198E
Version: 3
Valid from: Software V1.3

© SIGRIST-PHOTOMETER AG, technical details subject to change 08/2005

Instruction Manual StackGuard 2 System
10198E/3 i
Contents
1Equipment Description ................................................................................ 1
1.1 Overall view of the measuring system.................................................. 1
1.2 Scope of supply and accessories.......................................................... 2
1.2.1 Ring pipe .................................................................................... 2
1.2.2 Special accessories..................................................................... 2
1.3 Intended use and conformity ................................................................ 3
1.4 Product marking ................................................................................... 4
1.5 Technical data...................................................................................... 6
2Safety Rules................................................................................................ 8
2.1 Safety symbols used............................................................................ 8
2.2 Laser safety information....................................................................... 9
2.2.1 Laser data................................................................................... 9
2.2.2 Laser labels................................................................................. 9
2.3 What to do in an emergency .............................................................. 10
3Installation/Start-up ................................................................................... 11
3.1 Placement .......................................................................................... 11
3.2 Electrical connections......................................................................... 11
3.2.1 Instrument connections ............................................................ 11
3.2.2 Connections provided by customer ........................................... 11
4Operation .................................................................................................. 15
4.1 Elements on control unit SIGAR2 ....................................................... 15
4.2 Keypad and display ............................................................................ 17
4.2.1 Standby operation .................................................................... 17
4.2.2 Switching the installation on..................................................... 18
4.2.3 Displays shown during normal operation................................... 19
4.2.4 Display of malfunctions ............................................................ 20
4.2.5 Service mode............................................................................ 22
4.2.6 Switching the installation off .................................................... 23
4.3 Setting the national language ............................................................. 23
4.4 Setting the relay functions ................................................................. 24
4.5 Setting the access code ..................................................................... 26
4.6 Additional possibilities ........................................................................ 27
5Servicing................................................................................................... 28
5.1 Servicing schedule ............................................................................. 29
5.2 Checking the zero and reference points.............................................. 30
5.3 Checking the ring pipe ....................................................................... 34
5.4 Replacing filter (KZTN3) for purge air blower ..................................... 36
5.5 Replacing the desiccant...................................................................... 37
5.6 Replacing the purge air filter............................................................... 38
6Troubleshooting ........................................................................................ 39
6.1 Narrowing down the malfunction ....................................................... 39
6.2 Fault messages .................................................................................. 39
6.3 Customer service information............................................................. 43
7Taking Out of Service/Storage .................................................................. 45
8Packing/Transport ..................................................................................... 46

Instruction Manual StackGuard 2 System
ii 10198E/3
9Disposal.....................................................................................................47
10 Spare Parts ................................................................................................48
11 Appendix ...................................................................................................48
11.1 Service log ...................................................................................49
11.2 Fold-out orientation assistance for the measuring system ............53
12 Index .........................................................................................................55

Instruction Manual StackGuard 2 System
10198E/3 iii
Foreword
This Instruction Manual describes the basic functions for operating the
StackGuard. It is addressed to all persons who are responsible for operation of
the instrument.
Operate the instrument only after having familiarized yourself with the
contents of this Instruction Manual. In particular, be sure to study the section
on safety rules before starting operation!
Doc. No.
Title
Contents
10199E
Brief Instructions
Main functions and complete menu structure for
straightforward operation
10200E
Reference
Handbook
More sophisticated menu functions and
worksteps for advanced users
10201E
Service Manual
Repair and modification instructions for service
technicians
10202E
Questionnaire
Specifies the general conditions in which a
system operates
10221E
Parameter List
Configuration of the measuring system
Important instructions
Actions
Supplementary information
Extremely dangerous voltage
Warning: dangerous laser beams
Warning: high temperatures (danger of burns)
Separate disposal of electrical and electronic equipment
Fold-out assistance on subject of interest in the Appendix
Further
documentation
Symbols used in this
Manual
Fold-out assistance

Instruction Manual StackGuard 2 System
10198E/3 1
1Equipment Description
1.1 Overall view of the measuring system
Figure 1: Front view of measuring system
Standard version of
the ring pipe
Return pipe
with blower
Sampletaking
Sample
return
Supply pipe with heater
Shut-off valve in
sampling pipe
Sample divider
with sampling
cone
Mixing section
Off gas duct
Photometer
Control unit
SIGAR2
Purge air filter
Shut-off valve
in sample
return pipe
Emergency reset
for shut-off valves
Purge air blower

Instruction Manual StackGuard 2 System
2 10198E/3
1.2 Scope of supply and accessories
Units
Name
Versions/remarks
1
Photometer
StackGuard
1
Control unit
SIGAR2
1
Ring pipe
See 0
1
Instruction Manual
German, English
1
Reference Handbook
German, English
1
Brief Instructions
German, English
1
Checking rod
1.2.1 Ring pipe
The ring pipe is adapted to the particular measuring requirement and the local
conditions in collaboration with the customer. This means that the type and
number of the components used can differ from the standard version!
Usually a drawing is prepared for the specific measuring system and supplied
along with the documentation (Section 11).
You will find a list of all components used in your installation in the
Specification Sheet attached to this Instruction Manual.
1.2.2 Special accessories
Various special accessories are available for the StackGuard 2 system.
Information on the special accessories supplied is provided in the Specification
Sheet (see above).
Standard scope of
supply:
System-specific
drawing
Specification sheet

Instruction Manual StackGuard 2 System
10198E/3 3
1.3 Intended use and conformity
Use of the photometer for purposes other than those for which it was
designed can produce incorrect measuring results, possibly with process-
related consequential damage or even damage to the photometer itself!
The dust emissions system is designed for the measurement of particles in
gaseous, nonexplosive media up to 170° C.
The measuring system is assembled and configured at the factory for the
measurement duty specified by the user. The duty is specified with a
questionnaire that is an essential tool for defining the measuring system’s
intended use.
Current technological principles were followed in designing and manufacturing
the instru-ment. They comply with the applicable guidelines concerning safety
and duty to take due care.
The measuring instrument meets all applicable requirements within the European
Union (EU) for carrying the CE mark.
The system is tested in accordance with directives of the Federal Ministry for
Ecology, Nature Conservation and Reactor Safety by TÜV Rheinland, Cologne,
Institute for Energy Technology and Environmental Protection.
Intended use

Instruction Manual StackGuard 2 System
4 10198E/3
1.4 Product marking
Figure 2 Location of the Stackguard rating plate
The photometer’s rating plate carries the following informtion:
Figure 3: StackGuard rating plate
The photometer’s serial number is also stated in the * SYSTEM * menu
(Reference Handbook).
Position of the
rating plate on the
photometer
Date of manufacture
Designation of laser class
Country of
manufacture
Photometer designation
Serial No.
CE conformity
Special disposal of certain
components
Manufacturer data
Service voltage
Frequency
Power
Observe Instruction
Manual

Instruction Manual StackGuard 2 System
10198E/3 5
Figure 4 Location of the rating plate on SIGAR2
The SIGAR2 rating plate carries the following information:
Figure 5: SIGAR2 rating plate
Rating plate on the
control unit
Country of manufacture
Manufacturer
data
Serial No.
Service voltage
Power
CE conformity
Control unit designation
Date of manufacture
Frequency
Special disposal of certain
components
Observe Instruction
Manual

Instruction Manual StackGuard 2 System
6 10198E/3
1.5 Technical data
Measuring principle
scattered light measurement
Scatter angle
20°
Measuring span
0 .. 0.050 PLA to 0 .. 100 PLA
Resolution
0.0002PLA
Reproducibility
2% (referred to full scale)
Repeatability
0.5% (referred to full scale)
Linearity
0.5% (referred to full scale)
Temperature stability
4% in the -20° C to 50° C range (referred to full
scale)
Heat-up time
at least 2 h
Reaction time
less than 2 s (step response limit monitor)
Service interval
see servicing schedule (Section 5.1)
Power supply
3 x 340 .. 440 VAC, 50/60Hz
With neutral conductor for 230 VAC
Power input
5.5 kVA (standard version with 2 heaters)
1kVA per additional 1 kVA heater
1.5kVA per additional 1.5 kVA heater
2kVA per additional 2 kVA heater
Back-up fuse
max. 25 AT
Heat emission
3.5 kW (standard version with 2 heaters)
+50% of the additional heating capacity
Dimensions
see detailed dimension drawing in Section 11
Weight
about 240 kg (standard version)
Length of ring pipe
max. 25m total for supply and return
(one 90° elbow equals 1m of pipe length)
Connections to off
gas duct
DN65/ PN6 with flanges to DN2641 (or user-specific)
Protection degree of
entire installation
IP40
Maximum operating
altitude
3,000 m (9,900 ft) above sea level
Ambient temperature
-20 .. +50° C
Ambient humidity
0 .. 99% rel. humidity, noncondensing
Sample flow in ring
pipe
790 .. 930 l/min at 160°C
Measurement data
General data

Instruction Manual StackGuard 2 System
10198E/3 7
No. of measuring
ranges
8
Weight
about 8.4 kg
Enclosure
stainless steel, anodized aluminium
Protection degree
IP65
Material
stainless steel 1.4301
Window material
borosilicate, B270
Seals
FPM
Medium pressure
max. 3000 Pa (=30 mbar) against ambient pressure at
photometer location
Medium
temperature
max. 170° C
(the medium temperature must be adapted to make it
impossible for the medium to condense)
Sample flow
25 .. 50 l/min
Purge air
13 .. 16 l/min, max. 170° C
Interfaces
Profibus DP (optional)
RS-232 diagnostic interface
Weight
22 kg
Protection degree
IP65
Connections
2x 0/4 .. 20 mA, max. 600 
5x relay contacts max. 250 VAC, max. 4 A
digital inputs and outputs max. 5 V
Power input
230VAC
Power output
230VAC (during power failure)
Maximum load
195W
Maximum earth
leakage current
<2.7 mA
Photometer
Flow cell
SIGAR2 control unit
Optional standby
power supply

Instruction Manual StackGuard 2 System
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2Safety Rules
2.1 Safety symbols used
The symbols used on the instrument draw attention to the following safety
measures or precautions:
DANGER (BLACK ON YELLOW)
Danger of a general hazard.
This symbol marks areas or actions to which special safety rules apply. In
these cases consult the Instruction Manual!
VOLTAGE (BLACK ON YELLOW)
High voltage danger.
This symbol marks areas with live parts carrying voltages higher than 48 VAC
or higher than 65 VDC where electric shocks can occur. Consult the
Instruction Manual!
HOT (BLACK ON YELLOW)
Danger of hot surfaces.
This symbol marks covers on surfaces hotter than 80°C. For safe operation,
observe the Instruction Manual.
LASER RADIATION (BLACK ON YELLOW)
Danger of laser radiation.
This symbol marks covers that, when removed, can expose dangerous laser
radiation. Therefore these covers may be removed only in the deenergized
state and only by authorized service personnel!
Only trained personnel are allowed to open the standby power box for
resetting the shut-off valves (lethal danger)!
Operate the measuring system only in flawless condition and under strict
observance of the Instruction Manual!
Also observe the following points:
All components that come into contact with the sample are extremely hot.
Touching them without temperature-resistant gloves can result in severe
burns!
The measuring system should be operated only in the as-delivered
condition. Whenever elements are replaced, be sure to use only genuine
parts from the manufacturer!
Any changes to software parameters that are normally unavailable to the
user may compromise the safety of the measuring system!

Instruction Manual StackGuard 2 System
10198E/3 9
2.2 Laser safety information
Installed in the StackGuard is an encapsulated laser that corresponds to Class
1 (IEC 60825-1: 2001) with regard to all aspects of the instrument’s operation
and maintenance. Whenever the laser guards are removed for servicing
purposes, Class 3R laser radiation can be emitted. Hence these guards are
allowed to be removed only in the deenergized state by authorized service
personnel.
Caution –whenever operating or adjustment devices other than those
specified by Sigrist are used or different procedures are carried out, exposure
to dangerous radiation may result.
2.2.1 Laser data
Laser data IEC 60825-1: 2001
Laser medium: InGaAlP
Wavelength: 650nm
Emission time: cw
Radiant flux: 2mW
Radiant energy: -
Figure 6: Laser data
2.2.2 Laser labels
The following laser labels are applied to the StackGuard:
Figure 7: Laser labels
inside the
instrument:

Instruction Manual StackGuard 2 System
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2.3 What to do in an emergency
In an emergency, the main switch can be used to cut off power to the entire
installation. But this does NOT switch off the user’s signalling and control
cables or the standby power supply for controlling the valves, provided this is
supplied externally!
Action
1.
Turn the main switch to the zero position
(arrow)!
A

Instruction Manual StackGuard 2 System
10198E/3 11
3Installation/Start-up
3.1 Placement
The StackGuard 2 system must be installed at a weather-protected location on
a flat surface with sufficient load-bearing capacity.
3.2 Electrical connections
3.2.1 Instrument connections
Installation and initial start-up are carried out by an installation technician from
the SIGRIST country representative. The procedure is described in the
separately available Service Manual.
Observe the servicing interval stated in the Service Manual (Section 5) for
checking the ring pipe following initial start-up.
3.2.2 Connections provided by customer
Connecting live conductors causes grave danger to life and limb, and can
result in damage to parts of the installation!
Parts inside the photometer and the control unit may be energized with lethal
voltages. Before opening, make absolutely sure that no live conductors are
connected.

Instruction Manual StackGuard 2 System
12 10198E/3
Action
Remarks
1.
Remove protective cover (A) of the control unit.
2.
Loosen fastening screws (B) and swing down
the hinged frame (C).
Connection of the measured data outputs
can be done without swinging down the
hinged frame (C).
Figure 8: Large terminals.
The large terminals are designed for mains
voltage and can accommodate wires up to
2.5 mm2cross-section (without ferrules).
Open the terminals with a size 1
screwdriver!
Access to relay
outputs and
measured data
outputs
Terminal principles
A

Instruction Manual StackGuard 2 System
10198E/3 13
Terminals on
SIGAR 2
Used for
Remarks
1.
KL4 –KL5 –K6
Relay output 1
You can configure the relay
outputs any way you wish
(Reference Handbook).
KL8 –KL9 –K10
Relay output 2
KL12 –KL13 –K14
Relay output 3
KL16 –KL17 –K18
Relay output 4
KL20 –KL21 –KL22
Relay output 5
2.
334 –335
Measured data
output
0/4 .. 20 mA,
max. burden 600 
If not used, these terminals
have to be shorted with a
jumper!
Connecting the
relays and measured
data outputs

Instruction Manual StackGuard 2 System
14 10198E/3
Terminals on
SIGAR 2
Used for
Remarks
337 –338
Second
measured data
output
0/4 .. 20 mA,
max. burden 600 
If not used, these terminals
have to be shorted with a
jumper!
Details are given in the Reference Handbook.