Envea STACK 602 Manuale utente

STACK 602

USER MANUAL

STACK 602

Particulate Measurement System

USER MANUAL

Publication Part Number: PC-000848-MA

Publication Part No. PC-000848-MA

Issue 5

December 2021

Original language: English

document may be stored in a retrieval system,

transmitted, copied, or reproduced in any way, including,

but not limited to photocopy, photograph, magnetic or

other records without the prior agreement and permission

in writing of ENVEA UK Ltd.

Disclaimer

ENVEA reserves the right to revise and update this

documentation from time to time without obligation to

provide notification of such revision or change. Revised

documentation may be obtainable from ENVEA.

ENVEA reserves the right, without notice, to make changes

in equipment design or performance as progress in

engineering, manufacturing, or technology may warrant.

Trademarks

All product trademarks and registered trademarks are the

property of ENVEA UK Ltd.

All other product trademarks and registered trademarks

are the property of their respective companies.

envea™is a trademark of the ENVEA Group, France.

Feedback

ENVEA encourages customer feedback and welcomes

any comments or suggestions relating to the product or its

documentation.

Published by:

Technical Publications

ENVEA UK Ltd

ENVEA House

Rose & Crown Road

Swavesey, CAMBRIDGE

CB24 4RB, United Kingdom

Email: technicalpubli[email protected]

STACK 602 
ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021) v 
Table of Contents 
Table of Contents ............................................................................................... v 
List of Figures ...................................................................................................vii 
INTRODUCTION ____________________________________________ 9 
1 Purpose of this Manual ............................................................................... 9 
2 Product Safety .......................................................................................... 9 
2.1 Danger from Process ......................................................................... 9 
3 Safety Procedures ................................................................................... 10 
4 Intended Use .......................................................................................... 10 
5 Additional Information.............................................................................. 11 
5.1 Product Serial Numbers ................................................................... 11 
5.2 List of Abbreviations........................................................................ 11 
5.3 Related Documentation ................................................................... 11 
5.4 Product Parts and Options................................................................ 12 
6Certification ............................................................................................ 12 
6.1 Conformance and related Standards.................................................. 12 
TECHNICAL DATA _________________________________________ 13 
1 Process and Application Conditions ............................................................ 13 
2 Sensor Specification................................................................................. 13 
2.1 Dimensioned Drawings –Sensor Heads (Tx, Rx)................................. 14 
2.2 Quality Assurance and Control.......................................................... 15 
2.3 Sensor Options............................................................................... 15 
3 System Options....................................................................................... 16 
4 Cabling .................................................................................................. 16 
4.1 Data Cable Specifications................................................................. 16 
5PC Software Suite (PC-ME DUST TOOLS) .................................................... 17 
PRODUCT DESCRIPTION ____________________________________ 18 
1 System Overview .................................................................................... 18 
1.1 Sensor –DynamicOpacity® Transmitter/Receiver............................... 18 
1.2 Control Unit ................................................................................... 19 
2 Principle of Operation............................................................................... 20 
UNPACKING AND PREPARATION ______________________________ 21 
1 Unpacking and Inspection......................................................................... 21 
2 Network Layouts ..................................................................................... 21 
3 Prerequisites and Guidelines ..................................................................... 21 
3.1 Location Requirements .................................................................... 21 
3.2 Cabling and Cable Routing ............................................................... 22 
3.3 Grounding the Sensor ..................................................................... 22 
4 Supplying Purge Air –Purge Blower Unit .................................................... 23 
4.1 Mounting the Blower ....................................................................... 23 
4.2 Connecting the Purge Blower............................................................ 24 
4.3 Adjusting the Speed........................................................................ 25 
SENSOR INSTALLATION ____________________________________ 26 
1 Safety Information .................................................................................. 26 
2 Mounting the Sensor................................................................................ 26 
2.1 Transmitter and Receiver Heads ....................................................... 26 
2.2 Assembling the Head Mounting Components (Tx/Rx)........................... 27 
2.3 Fitting the Stack Mounting Stubs ...................................................... 28 

STACK 602 
vi (PC-000848-MA Issue 5, December 2021) ENVEA UK Ltd 
2.4 Setting up the Air Purges ................................................................. 29 
3 Connecting the Transmitter (Tx)................................................................ 29 
3.1 Transmitter/Receiver Connections..................................................... 30 
3.2 Transmitter/Receiver Link Settings ................................................... 30 
4 Connecting the Receiver (Rx).................................................................... 31 
4.1 Data Cable Connection .................................................................... 32 
5 Setting up the Receiver ............................................................................ 33 
5.1 Bus Termination Switch (SW101)...................................................... 33 
5.2 Set Address Switch (SW201)............................................................ 33 
5.3 Set Comms Settings (SW200) .......................................................... 34 
BASIC SYSTEM SETUP ______________________________________ 35 
1 User Controls and Functionality ................................................................. 35 
1.1 The ProController UI ....................................................................... 35 
1.2 The Standard Controller UI .............................................................. 36 
2 ProController –Function Keys and Setup .................................................... 37 
3 Main Menu Screens.................................................................................. 37 
3.1 Other Symbols ............................................................................... 38 
INITIAL SETUP ___________________________________________ 39 
1 Introduction............................................................................................ 39 
2 Power-up Checks..................................................................................... 39 
2.1 Checking the Comms Mode .............................................................. 39 
2.2 Performing a Master Reset ............................................................... 39 
3 Adding Sensors ....................................................................................... 40 
3.1 Detecting Devices Automatically (Autodetect) .................................... 40 
4 Editing Basic Sensor Settings .................................................................... 41 
4.1 Sensor Channels............................................................................. 42 
5 Adjust Sensor Brightness and Sensitivity .................................................... 42 
5.1 Adjusting Sensitivity/Brightness Automatically (Autoset) ..................... 42 
5.2 Adjusting Brightness and Sensitivity Manually .................................... 43 
6 Calibration Factor (Cal Factor)................................................................... 44 
6.1 Advanced Settings .......................................................................... 44 
QUALITY ASSURANCE AND SELF-TESTS ________________________ 45 
1 Available Sensor Tests ............................................................................. 45 
1.1 Performing Sensor Self-Tests ........................................................... 45 
1.2 Sensor Test Pass Levels................................................................... 45 
2 Opacity Self-Tests ................................................................................... 46 
2.1 Viewing Opacity Self-Tests............................................................... 46 
3 Dynamic Opacity (Dust) Self-Tests ............................................................ 47 
3.1 About DynamicOpacity®Self-Tests.................................................... 47 
3.2 Viewing Dynamic Opacity Self-Tests.................................................. 47 
4 Setting Sensor Tests and Alarms ............................................................... 48 
4.1 Enabling/disabling Self-Tests............................................................ 48 
4.2 Enabling/disabling Self-Test Alarms .................................................. 48 
MAINTENANCE____________________________________________ 49 
1 Safety Information .................................................................................. 49 
2 Maintenance Mode ................................................................................... 49 
2.1 Placing a Sensor in Maintenance Mode............................................... 50 
3 Service Messages .................................................................................... 51 
4 Inspecting and Cleaning Procedures........................................................... 52 

STACK 602 
ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021) vii 
9.4.1 Cleaning the Sensor Window (Rx and Tx) .......................................... 52 
9.5 Troubleshooting ...................................................................................... 52 
9.5.1 Comms Failure ............................................................................... 52 
9.5.2 Checking Spurs .............................................................................. 53 
9.5.3 Sensor Power Check........................................................................ 53 
9.5.4 Sensor Communications Check ......................................................... 53 
9.5.5 Power Loss .................................................................................... 53 
9.5.6 Frozen Readings ............................................................................. 54 
9.5.7 Troubleshooting Opacity .................................................................. 54 
9.5.8 Sensor Reading too Low or too High.................................................. 54 
APPENDIX A –ALIGNMENT ______________________________________ 57 
Principles of Alignment...................................................................................... 57 
Alignment Procedure ........................................................................................ 58 
APPENDIX B –CALIBRATION ____________________________________ 61 
Introduction .................................................................................................... 61 
Calculating the Calibration Factor ....................................................................... 61 
Calibration Procedure........................................................................................ 61 
Using the Calibration Tool.................................................................................. 62 
GENERAL NOTICES ____________________________________________ 64 
List of Materials................................................................................................ 64 
Recycling and Disposal of Electrical and Electronic Equipment ................................ 64 
INDEX ______________________________________________________ 65 
 
List of Figures 
Figure 1: Dimensional drawing of STACK 602 sensor. ........................................... 14 
Figure 2: STACK 602 with 100 mm (4”) mounting stubs for high-temperature applications.
...................................................................................................................... 15 
Figure 3: STACK 602 –DynamicOpacity®Transceiver/Receiver. ............................ 18 
Figure 4: Principle of Operation –DynamicOpacity®sensors. ................................. 20 
Figure 5: Wall-mounted Blower Unit (ACCAIR-B-Y)............................................... 24 
Figure 6: Purge blower wiring. ........................................................................... 25 
Figure 7: Speed selection for DynamicOpacity®sensors. ....................................... 25 
Figure 8: Installation diagram (for a sensor head). ............................................... 26 
Figure 9: Installing anti-fouling fittings. .............................................................. 27 
Figure 10: Attaching the sensor enclosure. .......................................................... 27 
Figure 11: Fitting the stack mounting stubs. ........................................................ 28 
Figure 12: Transmitter (Tx) PCB connections. ...................................................... 29 
Figure 13: Receiver (Rx) PCB connections. .......................................................... 31 
Figure 14: Basic setup –Communications settings. .............................................. 34 
Figure 15: ProController –User interface with controls.......................................... 35 
Figure 16: Standard Controller –User interface with controls................................. 36 
Figure 17: Screen elements (example). .............................................................. 38 
Figure 18: Running Autodetect (example). .......................................................... 40 
Figure 19: Main Setup screen. ........................................................................... 41 
Figure 20: Basic settings –Sensor channel.......................................................... 41 
Figure 21: Adjusting brightness and sensitivity. ................................................... 43 

STACK 602 
viii (PC-000848-MA Issue 5, December 2021) ENVEA UK Ltd 
Figure 22: Opacity sensor test results (alternating). ............................................. 46 
Figure 23: Dynamic Opacity sensor test results (alternating). ................................ 47 
Figure 24: Maintenance Mode screen. ................................................................. 50 
Figure 25: Placing sensor in Maintenance mode. .................................................. 50 
Figure 26: Alignment principles –Transmitter...................................................... 57 
Figure 27: Alignment principles –Receiver. ......................................................... 58 
Figure 28: Alignment tool.................................................................................. 58 
Figure 29: Aligning the Receiver (rotated view).................................................... 59 
Figure 30: Calibration tool screen (Edit mode). .................................................... 62 
Figure 31: Calculating the calibration factor automatically. .................................... 63 
 

STACK 602 9 Maintenance

ENVEA UK Ltd (PC-000848-MA Issue 5, December 2021) vii

1. Introduction

1.1 Purpose of this Manual

This manual contains all information necessary for the correct installation,

setup, operation, and maintenance of the instrument. The procedures given

in this manual must be carried out only by suitably trained and qualified

personnel.

1.2 Product Safety

The following symbols are used throughout this manual to indicate

procedures that, if not followed correctly, may result in personal injury or

damage to the equipment.

WARNING!

Alerts the user to a procedure or practice that can result in

personal injury or injury of others if not followed correctly.

CAUTION!

Alerts the user to a procedure or practice that can damage the

system or ancillary equipment if not followed correctly.

NOTES are used to highlight important information that assists the user in

carrying out a procedure or understanding the text.

In addition, the following symbols are used on the product:

WARNING! –ELECTRIC SHOCK

Protective Earth (GND) symbol

1.2.1 Danger from Process

The sensor may be installed in ducting that contains process particulate (and other

flue gas constituents) hazardous to health.

This may take one or more of the following forms:

Particulate which is flammable or explosive

Particulate which is toxic or in some other way hazardous to health

Particulate contained within high-temperature gas.

Take Precautionary Measures

Unless the process conditions are known to be entirely safe, suitable precautions,

such as the use of breathing apparatus or duct purging/ detoxifying, must be

employed before entry is made into the duct for installation or maintenance

purposes. If in doubt, consult your local Safety Officer and/or local safety

procedures.

9 Maintenance STACK 602

10 (PC-000848-MA Issue 5, December 2021) ENVEA UK Ltd

1.3 Safety Procedures

Always observe the following safety precautions. Personnel installing, operating,

or maintaining the equipment are responsible for their personal safety and the

correct handling and use of the equipment in accordance with the safety pro-

cedures detailed in this manual.

Follow all warnings and instructions marked on the product and in this manual.

These safety instructions must be followed to avoid possible personal injury, injury

to others, and damage to the product.

If the equipment is used in a manner not specified in this manual, the protection

provided by the equipment may be impaired. Retain these instructions in a safe

and known place for future use.

WARNING!

Risk of personal injury or injury to others. All personnel must be fully

trained and adhere to local and, where applicable, site-specific health

and safety laws and guidelines. –It is the responsibility of the local

organisations to enforce safe working practices at all times.

WARNING! –ELECTRIC SHOCK

Only connect to an earthed supply. The control unit is a Class 1

construction and must be connected to a protective earth connection

(GND).

WARNING! –ELECTRIC SHOCK

This product must be connected to a power supply of the same voltage

(V) and frequency (Hz) as indicated on the product rating plate and

provided in the Technical Data section of this manual.

A supply cable with an adequate rating must be used. Temperature

de-rating must be considered.

CAUTION!

Position the equipment to avoid excessive heat, vibration, humidity,

and dust.

CAUTION!

Failure to service or maintain the product, fitting non-approved parts

or carrying out non-approved alterations or servicing can be dangerous

and could affect the product's safety. It may also invalidate the terms

and conditions of the product warranty.

1.4 Intended Use

The STACK 602 particulate measurement sensor with DynamicOpacity®

technology is suitable for measurement in non-condensing applications, such as

electrostatic precipitators (ESPs), boilers, calciners, and large-diameter emission

stacks where dust levels are typically above 10 mg/m³ (and up to 1,000 mg/m³),

including processes that reach temperatures up to 600 °C (1,112 °F).

Limits of Use

Indice

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