SIGRIST StackGuard User manual

INSTRUCTION MANUAL
StackGuard
SIGRIST
Dust Concentration Monitor for
Hot Gasses
SIGRIST-PHOTOMETER AG
Hofurlistrasse 1
CH-6373 Ennetbürgen
Switzerland
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.photometer.com
Document No.: 10266E Version: 1 Valid from: 2006-07-01

© SIGRIST-PHOTOMETER AG, technical details subject to change 12/2006

Instruction Manual StackGuard
10266E/1 i
Contents
1Equipment Description .........................................................................1
1.1 Overall view of the measuring system............................................1
1.2 Scope of supply and accessories ...................................................1
1.3 Intended use and conformity.........................................................2
1.4 Product marking ..........................................................................3
1.5 Technical data ............................................................................5
2Safety Rules .......................................................................................7
2.1 Safety symbols used....................................................................7
2.2 Principles for safe handling ...........................................................7
2.3 Laser safety information...............................................................8
2.3.1 Laser data ...........................................................................8
2.3.2 Laser labels .........................................................................8
3Installation/Start-up .............................................................................9
3.1 Important information when installing the measuring system ............9
3.2 View of an installation example...................................................10
3.3 Installation of the photometer .....................................................11
3.4 Installation of the cooling section ................................................12
3.5 Installation of the purge air blower and coarse filter.......................13
3.6 Installation of the insulation shells ...............................................14
3.7 Installation of the control unit .....................................................14
3.8 Electrical installation ..................................................................16
3.9 Purge air heater connection ........................................................19
3.10 Initial commissioning..................................................................20
4Operation .........................................................................................21
4.1 Keypad and display....................................................................21
4.1.1 Displays shown during normal operation ...............................22
4.1.2 Display of malfunctions.......................................................22
4.1.3 Service mode.....................................................................23
4.2 Setting the national language......................................................24
4.3 Setting the measuring range .......................................................24
4.4 Setting the scaling and the unit...................................................26
4.5 Setting the relay functions..........................................................26
4.6 Setting the access code .............................................................30
4.7 Additional possibilities................................................................30
5Servicing..........................................................................................31
5.1 Servicing schedule.....................................................................31
5.2 Checking the zero and reference points........................................32
5.3 Replacing filter (KZTN3) for purge air blower ................................35
5.4 Replacing the desiccant..............................................................36
5.5 Replacing the purge air filter .......................................................37
6Troubleshooting ................................................................................38
6.1 Narrowing down the malfunction.................................................38
6.2 Fault messages .........................................................................38
6.3 Customer service information......................................................40
7Taking Out of Service/Storage ............................................................42

Instruction Manual StackGuard
ii 10266E/1
8Packing/Transport ............................................................................. 43
9Disposal........................................................................................... 44
10 Spare Parts ...................................................................................... 45
11 Appendix ......................................................................................... 46
12 Index............................................................................................... 47

Instruction Manual StackGuard
10266E/1 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
10267E Brief Instructions Main functions and complete menu structure for
straightforward operation
10268E Reference
Handbook
More sophisticated menu functions and
worksteps for advanced users
10269E Service Manual Repair and modification instructions for service
technicians
10145DE Questionnaire Specifies the general conditions in which a
system operates
10271DE 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
Further
documentation
Symbols used in this
Manual

Instruction Manual StackGuard
iv 10266E/1

Instruction Manual StackGuard
10266E/1 1
1Equipment Description
1.1 Overall view of the measuring system
Pos. Name
1 Photometer with
measuring cell
2 Inlet tube
3 Connecting cable to
purge air heater
4 Control unit
5 Power cable
6 Connecting cable
between photometer
and control unit
7 Outlet tube
8 Coarse filter for
purge air blower
9 Purge air blower
10 Purge air filter
11 Cooling section
Figure 1: Overview of the measuring system
1.2 Scope of supply and accessories
Units Name Versions/remarks
1 Photometer StackGuard
1 Control unit SIREL SMD
1 Instruction Manual German, English
1 Reference Handbook German, English
1 Brief Instructions German, English
1 Purge air blower
1 Coarse filter
2 Insulation shells
1 Cooling section
2 Inlet and outlet tubes
1 Checking rod
Standard scope of
supply:

Instruction Manual StackGuard
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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 photometer is designed for the measurement of particles in gaseous,
nonexplosive media up to 170° C.
The photometer 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.
State-of-the-art rules of engineering practice were observed in the design and
manufacture of the measuring system. They comply with the usual directives
relating to safety and the obligation to exercise due care.
The dust concentration monitoring instrument meets the requirements
applicable within the European Union (EU):
Electromagnetic Compatibility (EMC)
Low Voltage Directives (LVD)
Standards for the safety of laser installations IEC 60825 1:2001
EN 14181:2004 and DIN EN ISO 14956
Therefore the photometer carries the CE mark.
Intended use

Instruction Manual StackGuard
10266E/1 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 INFO* menu
(→Reference Handbook).
Position of the
rating plate on the
photometer
Date of manufacture
Designation of laser class
Country of manufacture
Photometer desi
g
nation
Serial No.
CE conformity
Special disposal of certain
components
Manufacturer data
Operating voltage Frequency
Power
Observe Instruction
Manual

Instruction Manual StackGuard
4 10266E/1
Every control unit has an identification plate with the instrument number and
electrical connection information:
Figure 4 Location of the control unit rating plate
You will find the instrument number of the photometer in the
−*SYSTEM INFO*/Instrument no. −menu (→Reference Handbook).
The SIREL rating plate carries the following information:
Figure 5: SIREL rating plate
Rating plate on the
control unit
Country of manufacture
Manufacturer data
Serial No.
Operating voltage
Power
CE conformity
Control unit designation
Date of manufacture
Frequency
Special disposal of certain
components
Observe Instruction
Manual

Instruction Manual StackGuard
10266E/1 5
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)
Environment -20 .. +50° C
Service interval see servicing schedule (→Section 5.1)
Operating voltage 24 VDC (from control unit)
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 12 .. 16 l/min, max. 170° C
Measurement data
Photometer
Flow cell

Instruction Manual StackGuard
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Operating voltage 85 .. 264 V; 47 .. 63 Hz or 24 VDC; 25 W
Space requirements SIREL SMD: 200 mm x 157 mm x 96 mm
SIREL robust: 220 mm x 160 mm x 90 mm
(See Section …… for detailed dimension sheet.)
Interfaces Profibus DP (optional)
Weight SIREL SMD: approx. 1.5 kg
SIREL robust: approx. 2.0 kg
Protection index IP65
Connections 0/4 .. 20 mA, max. 600 Ω, max. 24 V
with galvanic isolation, max. 50V
relative to earthing
Relay contacts max. 250 VAC, max. 4 A
Digital inputs/outputs max. 5 V
Standard cable Length: 5 m / 4-core
SIREL SMD control
unit

Instruction Manual StackGuard
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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!
2.2 Principles for safe handling
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 measurement sample may
have a high temperature. To avoid serious burns, wear temperature-
resistant gloves !
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
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2.3 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.
2.3.1 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
2.3.2 Laser labels
The following laser labels are applied to the StackGuard:
Figure 7: Laser labels
inside the
instrument:

Instruction Manual StackGuard
10266E/1 9
3Installation/Start-up
3.1 Important information when installing the
measuring system
The purge air blower must be sized so that a purge air quantity of 12..16
l/min. is guaranteed under all pressure conditions in the measuring cell.
A coarse filter must be installed before the purge air blower.
The cooling section must be installed between purge air blower and purge
air filter. Its purpose is to cool down the purge air that is heated by the
compression of the purge air blower.
At an ambient temperature of 50°C, the purge air temperature at the
purge air filter must not exceed 50°C!

Instruction Manual StackGuard
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3.2 View of an installation example
Pos. Name
1 Photometer
2 Purge air heater
3 Connecting cable to
purge air heater
4 Control unit
5 Power cable
6 Connecting cable be-
tween photometer and
control unit
7 Coarse filter for purge
air blower
8 Connection hose be-
tween coarse filter
and purge air blower
9 Purge air blower
10 Connection hose
(450 mm) between
purge air blower and
cooling section
11 Cooling section
12 Purge air filter
13 Connection hose
(950 mm) between
cooling section and
purge air filter
Figure 8: Overview of installation components
Example of a meas-
uring system

Instruction Manual StackGuard
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3.3 Installation of the photometer
Pos. Name
1 Mounting plate
2 Mounting bracket (cus-
tomer-side)
3 Photometer mounting
bracket
4 Purge air filter
Figure 9: Photometer installation
Action Remarks
1. Fasten the mounting plate (1) with the two
mounting brackets vertically on a wall.
The holes for the mounting brackets (2)
have to be drilled in the mounting plate (1) by
the customer!
→Figure 9
2. Fasten the photometer to the mounting
bracket (3) with the screws for that purpose.
→Figure 9

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3.4 Installation of the cooling section
Pos. Name
1 Connection hose (950 mm)
between cooling section outlet
and purge air filter
2 Cooling section outlet
3 Cooling section (consisting of
two aluminum tubes)
4 Connection hose (40 mm)
5 Three tube clamps
6 Cooling section inlet
7 Connection hose (450 mm)
between cooling section inlet
and purge air blower
8 Purge air blower
9 Purge air filter
Figure 10: Cooling section installation example
Action Remarks
1. Fix the tube clamps (5) to the desired posi-
tion on the wall as shown in the figure.
2. Connect the two aluminum tubes (3) with
the 40 mm long hose piece (4).
Place the entire unit into the prefixed tube
clamps (5).
→Figure 10
3. Fasten the 950 mm long hose section (1)
to the cooling section outlet (2).
Attach the other end of the hose onto the
purge air filter (9).
→Figure 10

Instruction Manual StackGuard
10266E/1 13
Action Remarks
4. Fix the 450 mm long hose section (7) to
the cooling section inlet (6).
This hose section will be connected to
the purge air blower later!
→Figure 10
3.5 Installation of the purge air blower and coarse
filter
Pos. Name
1 Connection hose
(450 mm) between
cooling section inlet and
purge air blower
2 Purge air blower
3 Connection hose
between purge air
blower and coarse filter
4 Coarse filter for purge
air blower
Figure 11: Purge air blower and coarse filter installation
Action Remarks
1. Place the purge air blower (2) on the ground or
on a firm surface.
→Figure 11
2. Fix the coarse filter (4) to the desired position. →Figure 11
3. Connect the coarse filter outlet with the air
intake supports of the purge air blower to the
connection hose section (3)
→Figure 11
4. Fix the hose (450 mm long) coming from the
cooling section inlet onto the purge air blower
inlet.
→Figure 11

Instruction Manual StackGuard
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3.6 Installation of the insulation shells
Pos. Name
1 Purge air heater
2 Measuring cell outlet
Figure 12: Insulation shell position
Action Remarks
1. Attach the two insulation shells at positions (1)
and (2) on the photometer.
The insulation shells consist of two parts
that are placed around the tube pieces and are
held together by means of quick-release locks
(see figure).
→Figure 12
3.7 Installation of the control unit
The control unit can be installed directly on the wall, in a built-in grill, or on an
instrument stand.
The length of the standard cable is 5 m. The control unit can therefore be
positioned directly near the photometer if required.
Figure 13: Control unit position with standard cable
SIREL installation
Distance
up to 5 m