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Land 4500 MKII Premier Operation And Maintenance Manual

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Operation and Maintenance Manual
Model 4500 Premier
Publication No 770.084
Language English
Combustion & Environmental Monitoring

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Summary of Contents for Land 4500 MKII Premier

  • Page 1 Operation and Maintenance Manual Model 4500 Premier Publication No 770.084 Language English Combustion & Environmental Monitoring...
  • Page 3 How to Get Further Assistance If further assistance is required please contact your nearest Land Instruments International office at the following addresses or your local distributor (see our web site for details http://www.landinst.com). Italy Land Instruments SRL Land Instruments International Via dell’Industria, 2...
  • Page 5 Health and Safety Information Equipment Operation Use of this instrument in a manner not specified by Land Instruments International may be hazardous. Electrical Power Supply Before working on the electrical connections all of the electrical power lines to the equipment must be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these operating instructions.

  • Page 6: Design And Manufacturing Standards

    This manual is provided as an aid to owners of a Land Instruments International’s products and contains information proprietary to Land Instruments International. This manual may not, in whole or part, be copied, or reproduced without the expressed written consent of Land Instruments International Ltd.
  • Page 7 Contents Ref. Description Page Design and Manufacturing Standards Signs and Symbols Used on Equipment and Documentation INSTALLATION Ref. Description Page General Description Installation Diagram Installation Instructions A3-1 Installation Checklist A3-2 Selecting an Installation Location A3-3 Maintaining the Measurement Pathlength During Installation A3-4 Installing the Mounting Flanges A3-5...
  • Page 8 OPERATION Ref. Description Page Getting Started B1-1 The User Interface B1-2 Function Keys B1-3 Glossary of Terms B1-4 Using the Instrument for the First Time Normal Modes of Operation B2-1 Alarm Setup B2-2 Output Setup B2-3 MODBUS Communications Periodic Modes of Operation B3-1 Calibration Check B3.2...

  • Page 9: Table Of Contents

    REFERENCE Ref. Description Page Theory of Operation and Application C1-1 General Outline C1-2 Beer-Lambert’s Law C1-3 Optical Pathlength Ratio (OPLR) C1-4 Examples of Different Optical Pathlength Ratios (OPLR) Requirements for Environmental Legislation Physical Principles C3-1 General Description C3-2 Principle of Operation User Interface C4-1 Operational Structure...

  • Page 11: A1 General Description

    The Model 4500 Premier is designed for continuous operation in all weather conditions. Maintenance requirements are minimal. The Land Instruments International Model 4500 Premier Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam through flue gases. An internal microprocessor calculates dust density and other parameters.
  • Page 12 Model 4500 Premier Dust and Opacity Monitor Analogue Output The Model 4500 Premier Dust and Opacity Monitor has two current loop outputs available. Each one may be set independent of the other to output one of the six functions below: Opacity Dust Constant Current...

  • Page 13: A2 Installation Diagram

    Model 4500 Premier Dust and Opacity Monitor Installation Diagram DANGER CAUTION SYSTEM OK SPAN CALIBRATE ZER O CALIBRATE ALARM CALIBRATE OP ACITY & DUS T MONITOR The Model 4500 Premier Dust Opacity Monitoring System showing all components installed. Control Room Unit (CRU) Model 4500 Premier Transceiver Control Room Unit (CRU) Power Input Model 4500 Premier Retro-Reflector...

  • Page 14: A3 Installation Instructions

    Model 4500 Premier Dust and Opacity Monitor Installation Instructions A3-1 Installation Checklist Select the installation location. Install the mounting flanges. Install the Air Blower Unit(s) for the purge air supply. Consult the Air Blower Unit Instruction Manual for full details. The purge air supply must be connected and working before the Transceiver and the Retro-Reflector are installed.

  • Page 15: A3-2 Selecting An Installation Location

    Measurement errors may result if the Transceiver is subjected to strong vibrations or if the stack or duct changes shape as the gas temperature changes. If this cannot be avoided, a vibration free mounting can be installed. Contact Land for information. The ambient temperature at the mounting location must remain between -20°C and +55°C (-4°F and 131°F).

  • Page 16: A3-3 Maintaining The Measurement Pathlength During Installation

    Model 4500 Premier Dust and Opacity Monitor A3-3 Maintaining the Measurement Pathlength During Installation The flange-to-flange pathlength is defined as the distance between the Transceiver air purge flange and the Retro-Reflector air purge flange. The flange-to-flange pathlength is specified at the time of order and is factory set. This measurement pathlength is indicated on the back of the Transceiver.
  • Page 17 If the diameter of the stack is too large (over 2 m / 6.5 ft) to use an alignment tube, Land can supply an optical flange alignment tool (Part number 702.787). Contact Land for more information.

  • Page 18: A3-5 Mounting Details

    Model 4500 Premier Dust and Opacity Monitor A3-5 Mounting Details Air Purge Mounting Holes The air purge unit must be fixed to the mounting flange. It has three mounting holes to accept the mounting studs from the Standpipe. ø190 (7.50) Front view of Air Purge showing mounting holes...

  • Page 19: A3-6 Using The Flange Alignment Tool

    Model 4500 Premier Dust and Opacity Monitor A3-6 Using the Flange Alignment Tool The flange alignment tool (part number 702.787) consists of two plates which are mounted on to the flanges. One plate supports a light source, the other a small telescope with a target in the centre. When the flanges are properly aligned, the light spot is located in the centre of this target.

  • Page 20: A3-7 Important Information For Installing The Transceiver And Retro-Reflection

    Model 4500 Premier Dust and Opacity Monitor A3-7 Important Information for Installing the Transceiver and Retro-Reflection 1000 (39) 520 (20.5) 240 (10) 240 (10) 320 (13) 1000 (39) 440 (17) 1000 (39) 1000 (39) 638 (25) 240 (10) 240 (10) 220 (9) 500 (20) 580 (23)

  • Page 21: A3-8 Mounting The Transceiver And Retro-Reflector

    Model 4500 Premier Dust and Opacity Monitor A3-8 Mounting the Transceiver and Retro-Reflector Ideally the instrument should be installed when the process is not operating and the stack is cold. The air blower unit should operating and connected to the Transceiver and Retro-Reflector before the instrument is mounted on to the flanges.

  • Page 22: A3-9 Installing The Termination Box

    Model 4500 Premier Dust and Opacity Monitor A3-9 Installing the Termination Box The connection interface for the Land Instruments International Model 4500 Premier Dust and Opacity Monitor is the Termination Box. This is protected to IP65(NEMA4). The warranty on the instrument may be invalidated if entry fittings...

  • Page 23: A3-10 Electrical Connections

    Model 4500 Premier Dust and Opacity Monitor A3-10 Electrical Connections All switch cabinets, distribution boxes, fuses and other components for electrical installation must be provided by the customer, as must the mains power supply connections. Installation should be carried out by a competent person and cables should satisfy current carrying capacity and voltage rating.

  • Page 24: A3-11 Cable Specification

    Model 4500 Premier Dust and Opacity Monitor A3-11 Cable Specification Cable types recommended by Land. Electrical No. of Core Size Core Size Core Size Screened Supplied Connections Cores strands/dia Overview 16/0.2 LAND 0.5 to 1.5 16/0.2 to 30/0.2 22 to 16 Customer 1.5 to 4.0 16/0.2 to 56/0.3...

  • Page 25: A3-12 Termination Box Connections

    Model 4500 Premier Dust and Opacity Monitor A3-12 Termination Box Connections Isolate the mains supply before making any connection to the WARNING Termination Box. This instrument must be earthed/grounded. Risk of electric shock. Cable entries are not supplied as standard. The blank plate may be removed and cut out for suitable conduit or other type of entry.

  • Page 26: A3-13 Control Room Unit Connections

    Model 4500 Premier Dust and Opacity Monitor A3-13 Control Room Unit Connections The Control Room Unit is displays data and status information. Make connections as described in the table below. For full details refer to Control Room Unit Operating Instruction (Part Number 770.043). Function Termination Box CLOP 1+...

  • Page 27: A3-14 Modbus Connections

    Model 4500 Premier Dust and Opacity Monitor A3-14 MODBUS Connections The communication protocol fitted as standard on the Model 4500 Premier is the MODBUS protocol. Based on the RS232 or RS485 hardware standards it provides direct access to system data via the T- Box terminal connections 38 - 43.
  • Page 28 Model 4500 Premier Dust and Opacity Monitor...

  • Page 29: B1 Getting Started

    Model 4500 Premier Dust and Opacity Monitor Getting Started B1-1 The User Interface The Model 4500 Premier is operated from the User Interface in the Transceiver. The User Interface is operated via various function keys. It has five illuminated indicators, a contrast control and a maintenance key.

  • Page 30: B1-2 Function Keys

    Model 4500 Premier Dust and Opacity Monitor B1-2 Function Keys The following function keys are located on the user interface. Function ENTER Generally used for selecting menu items and for making and saving changes. Scrolls the main and secondary menus Scrolls sub menus and selects/alters parameters for changes EXIT Returns to the previous menu level.

  • Page 31: B1-3 Glossary Of Terms

    Model 4500 Premier Dust and Opacity Monitor B1-3 Glossary of Terms Op ....... Opacity O.D......Optical Density Dust ......Dust Density Averaging 1 ....Time period used to calculate block average of output 1 Averaging 2 ....Time period used to calculate block average of output 2 Status ......

  • Page 32: B1-4 Using The Instrument For The First Time

    ‘OPLR’ is displayed. ↑↓ OPLR: ↑↓ If the OPLR is correct press the ‘EXIT’ key to return to the menu spine. If it is incorrect, the instrument must be returned to Land EXIT Instruments International for reprogramming. Opacity: 0.0% Now set the instrument to alignment mode.
  • Page 33 Model 4500 Premier Dust and Opacity Monitor Set the Instrument to ‘Align’ Mode Accurate alignment is essential if the Model 4500 Premier is to function correctly and meet its design specification. Opacity: 0.0% ↵ ↵ ↵ ↵ ↵ ↑↓ Faults: Scroll through the menu spine using the ↑...
  • Page 34 Model 4500 Premier Dust and Opacity Monitor Align the Retro-Reflector Quick Release Clip Captive Socket Head Screws Opening the Retro-Reflector Case & Releasing the Reflector Open the Retro-Reflector case by undoing the two quick-release clamps. Release the Retro-Reflector Mount by unscrewing the two captive socket head screws on either side of the Retro-Reflector Mount and allow the Retro-Reflector to drop into a horizontal position.
  • Page 35 Model 4500 Premier Dust and Opacity Monitor Align the Transceiver Transceiver Alignment Target Observe the alignment target through the window (3). A bright green spot (4) should be visible. To move the green spot horizontally adjust M12 nut (1) on the air purge flange and to move it vertically, adjust the M12 nuts (2), also on the air purge flange as illustrated above.
  • Page 36 Model 4500 Premier Dust and Opacity Monitor Setup Calibration Check Intervals Opacity: 0.0% The Model 4500 Premier Dust and Opacity Monitor may be programmed to ↵ ↵ ↵ ↵ ↵ ↑↓ Faults: perform a calibration check at preset intervals. Alternatively the timer can be disabled (set time interval to zero) and the instrument will calibrate only in ↑↓...
  • Page 37 Model 4500 Premier Dust and Opacity Monitor Press the ‘ENTER’ (↵ ↵ ↵ ↵ ↵ ) key from the ‘Cal Setup’ display to Opacity: 0.0% return to the ‘Cal Setup’ menu. Scroll through the ‘Cal ↵ ↵ ↵ ↵ ↵ ↑↓...
  • Page 38 Model 4500 Premier Dust and Opacity Monitor Setup Current Loop Outputs Opacity: 0.0% ↵ ↵ ↵ ↵ ↵ ↑↓ Faults: The Model 4500 Premier Dust and Opacity Monitor has two ↑↓ independent customer outputs available. Each signal output interval may be altered by setting the ‘Average 1’ and ‘Average 2’ displays accordingly.
  • Page 39 Model 4500 Premier Dust and Opacity Monitor Use the ← and → keys to select the required option for Output ↵ ↵ ↵ ↵ ↵ ↔ Outputs 1: 1 and then press the ‘ENTER’ (↵ ↵ ↵ ↵ ↵ ) key (notice no underlined Opacity character).
  • Page 40 Model 4500 Premier Dust and Opacity Monitor To set the second customer output, use the ↑ and ↓ keys to Opacity: 0.0% select ‘Output 2’ and then press the ‘ENTER’ (↵ ↵ ↵ ↵ ↵ ) key. ↵ ↵ ↵ ↵ ↵ ↑↓...
  • Page 41 Model 4500 Premier Dust and Opacity Monitor 12. Once the required averaging time period has been selected and Averaging 1: set, press the ‘EXIT’ key to return to the ‘Averaging 1’ display. EXIT 13. To set the averaging option for the second customer output, use the ↑...
  • Page 42 Model 4500 Premier Dust and Opacity Monitor Setup Alarms Opacity: 0.0% ↵ ↵ ↵ ↵ ↵ ↑↓ Faults: The Model 4500 Premier has two customer alarms available. Each alarm may be set to trip at a specified level for Optical Density, Opacity or Dust. A ↑↓...
  • Page 43 Model 4500 Premier Dust and Opacity Monitor Use the ← and → keys to select the required measurement Opacity: 0.0% (Optical Density, Opacity or Dust) to be alarmed and then AL1 type: Opacity press the ‘ENTER’ (↵ ↵ ↵ ↵ ↵ ) key (notice no underlined character). Press the ↑...
  • Page 44 Model 4500 Premier Dust and Opacity Monitor Perform Calibration Check The instrument will be ready for use on completion of ‘Cal check’. The simplest way to perform this is as follows: Power down the instrument. Power up the instrument and a calibration check will be performed automatically. Allow three minutes for the calibration check to be completed and then check that the ‘System OK’...
  • Page 45 Model 4500 Premier Dust and Opacity Monitor MODBUS Option MODBUS is a communications system based on the RS232 or RS485 duplex hardware standards and provides direct access to the Model 4500 Premier system data via the Termination Box. It is a standard feature on this model.
  • Page 46 Model 4500 Premier Dust and Opacity Monitor Setup Menu MODBUS Options Set ‘Station Number’ and ‘Link’ options on the ‘Miscellaneous’ menu under ‘Setup’ on the menu spine (see section C4-4 Setup Screens). The Model 4500 Premier has two options that require setting for correct Opacity: 0.0% use of the MODBUS communications protocol.
  • Page 47 Model 4500 Premier Dust and Opacity Monitor The Station Number indicates the location of the Opacity: 0.0% instrument to the user control system via the MODBUS Station number: communication protocol. Press the ↑ or ↓ key to select the required value then press the ‘ENTER' (↵ ↵ ↵ ↵ ↵ ) key to set ↑↓...

  • Page 48: B2 Normal Modes Of Operation

    Model 4500 Premier Dust and Opacity Monitor Normal Modes of Operation B2-1 Alarm Setup The Model 4500 Premier has two customer alarms available. Each alarm may be set to trip at a specified level for Optical Density, Opacity or Dust. A delay of between 0 to 30 seconds is also available for each alarm.
  • Page 49 Model 4500 Premier Dust and Opacity Monitor Use the ← and → keys to select the required measurement Opacity: 0.0% (Optical Density, Opacity or Dust) to be alarmed and then press AL1 type: Opacity the ‘ENTER’ (↵) key (notice no underlined character). Press the ↑...

  • Page 50: B2-2 Output Setup

    Model 4500 Premier Dust and Opacity Monitor B2-2 Output Setup The Model 4500 Premier Dust and Opacity Monitor has two independent customer outputs available. Each signal output interval may be altered by setting the ‘Average 1’ and ‘Average 2’ displays accordingly. Press and hold the maintenance key for a period of 3 seconds, until the red LED illuminates.
  • Page 51 Model 4500 Premier Dust and Opacity Monitor Use the ← and → keys to select the required option for Output 1 ↵ ↵ ↵ ↵ ↵ ↔ Outputs 1: and then press the ‘ENTER’ (↵) key (notice no underlined Opacity character).
  • Page 52 Model 4500 Premier Dust and Opacity Monitor To set the second customer output, use the ↑ and ↓ keys to Opacity: 0.0% select ‘Output 2’ and then press the ‘ENTER’ (↵) key. Repeat ↵ ↵ ↵ ↵ ↵ ↑↓ Output 1: steps 5 to 7 above.
  • Page 53 Model 4500 Premier Dust and Opacity Monitor 11. Set the hours (h) by pressing the ← and → keys and then the Averaging 1: ‘ENTER’ (↵) key. Set the minutes (m) and seconds (s) in a similar way. → ← Continue to step 12 ↵...
  • Page 54 Model 4500 Premier Dust and Opacity Monitor 12. Once the required averaging time period has been selected and Averaging 1: set, press the ‘EXIT’ key to return to the ‘Averaging 1’ display. EXIT 13. To set the averaging option for the second customer output, use Opacity: 0.0% the ↑...

  • Page 55: B2-3 Modbus Communications

    Model 4500 Premier Dust and Opacity Monitor B2-3 MODBUS Communications MODBUS is a communications system based on the RS232/RS485 three wire half duplex hardware standard and provides direct access to the Model 4500 Premier system data via the instrument serial port.

  • Page 56: Description

    Model 4500 Premier Dust and Opacity Monitor Commands Mobus communications will be limited to the following command subset: Command MODBUS Function Notes Read Holding Register Read Register (single or block) Pre-set Register Write to Single Register 10 (Hex) Pre-set Multiple Registers Write to Multiple Registers NOTE (03)

  • Page 57: Description

    Model 4500 Premier Dust and Opacity Monitor System Data Register Table NOTE Certain registers are read-only. Any attempt to write to these registers will result in the return of an error code. Register # Parameter Data Description Range Write Type Access OPLR Float...
  • Page 58 Model 4500 Premier Dust and Opacity Monitor Register # Parameter Data Description Range Write Type Access OP1 Span Float CLOP 1 range 0.0 - 3.0 Optical Density optical density OP1 Span Float CLOP 1 range 0.0 - 1.0 Opacity opacity OP1 Span 16-bit CLOP 1 range...
  • Page 59 Model 4500 Premier Dust and Opacity Monitor *Further Information On Registers Error Flags (Register 87 & 88) CHECKSUM ERROR 0x0000001 Eeprom checksum failure NOT USED 0x0000002 NOT USED -1 ≤ Op0 ≤ 2 OP0 FAULT 0x0000004 -1 ≤ OpC ≤ 2 OPC FAULT 0x0000008 -0.05 -1 ≤...
  • Page 60 Model 4500 Premier Dust and Opacity Monitor Calibration Status (Register 106) PENDING ZERO CHECK ZERO TIMING UPSCALE CHECK UPSCALE TIMING MOTOR CHECK FINALISE ABORTING CAL START CAL CHECK CALC CONSTANTS 10 NOT USED 11 SET BALANCE 12 EXTERNAL STANDARD 13 IN FACTORY CAL 14 IN CAL AUDIT 15 IN RECAL 16 WAITING...
  • Page 61 Model 4500 Premier Dust and Opacity Monitor Calibration Phases (Register 168) Three bits in this register are defined: all other bits are zero. If one bit is true then the others are false. Bit 0 Zero Phase True during a Calibration Check sequence. Goes true Cal Action delay seconds before the zero reflector starts to drive in.
  • Page 62 Model 4500 Premier Dust and Opacity Monitor (06) Preset Register Query Response Slave Address Slave Address Function Function Register Address Hi Register Address Hi Register Address Lo Register Address Lo Data Hi Data Lo Data Lo Data Hi CRC Hi CRC Hi CRC Lo CRC Lo...
  • Page 63 Model 4500 Premier Dust and Opacity Monitor Error Codes The Model 4500 Premier may return the following MODBUS exception codes. Code Exception Description ILLEGAL FUNCTION The instrument only responds to codes 03, 06 and 10 (Hex). Any other function request will result in the return of this error.

  • Page 64: B3 Periodic Modes Of Operation

    Model 4500 Premier Dust and Opacity Monitor Periodic Modes of Operation B3-1 Calibration Check Transceiver Source LED Detector D Flood LED Concave Mirror 50/50 Beam Splitter Span Filter Collimating Lens 10. Zero Point Reflector Collimated Beam 11. Automatic Fail Safe Shutter (Optional) Detector D The Transceiver periodically performs a two step calibration check.

  • Page 65: B3.2 Calibration Audit

    Model 4500 Premier Dust and Opacity Monitor B3.2 Calibration Audit A convenient Calibration Audit facility is provided, for carrying out the Calibration Audit tests required by USEPA and other Environmental Regulatory Authorities. Calibration Audit and Modbus Communications When the instrument is in maintenance mode Modbus communications are disabled. It is therefore not possible in this mode to monitor the results of the Calibration Audit and Response Time tests using the Modbus.
  • Page 66 Model 4500 Premier Dust and Opacity Monitor Read and record the displayed opacity value. The instrument should read a value within ±1.0 % of the calibration filter. Note that this value will be corrected for the Optical Path length Ratio (OPLR).

  • Page 67: B3-3 Re-Calibration

    Re-calibration must be carried out by a Land Service Engineer or other competent person. If the flange to flange path length is altered (i.e. due to relocation of the instrument) contact Land customer services for instrument pathlength setup advice.

  • Page 68: B3-4 Isokinetic Calibration

    Model 4500 Premier Dust and Opacity Monitor B3-4 Isokinetic Calibration The Model 4500 Premier measures the opacity of dust and smoke emissions. As explained in the Reference manual, this value is related to the dust density in the stack, through the Beer-Lambert law (see section C1- 2).
  • Page 69 Model 4500 Premier Dust and Opacity Monitor Setting the Dust Gain value (single gravimetric value) The Model 4500 Premier menu program contains a particularly simple method for calibrating the Dust Gain parameter against a single isokinetic sample. When preparations for doing an isokinetic sample are in place, press the Maintenance key for 3 seconds until the LED is illuminated.
  • Page 70 Model 4500 Premier Dust and Opacity Monitor Setting the Dust Gain value (multiple isokinetic samples) When preparations for doing an isokinetic sample are in place, press the Maintenance key for 3 seconds until the LED is illuminated. Enter the password using the ↑ and ↓ keys, then press the ‘ENTER’...
  • Page 71 Model 4500 Premier Dust and Opacity Monitor When all the samples have been analysed gravimetrically, it will be possible to plot a graph of dust density against average optical density for each of the samples. Plot a 'best fit' straight line passing through the origin as shown below.

  • Page 72: B3-5 M203 Clear Stack Simulator

    Model 4500 Premier Dust and Opacity Monitor B3-5 M203 Clear Stack Simulator Checklist The M203 Clear Stack Simulator System (Part number 703.902) contains the following: M203 Clear Stack Simulator Spare Apertures for M203 Simulator Spare Apertures for Dust Span Filter Spare Apertures for Dust Zero Reflector Allen Keys Allen Keys...
  • Page 73 M203 is only used with the instrument it has been calibrated with. Please ensure the plant installation location (i.e. Stack 1) is written on the carry case label before placing the clear sticky label (Provided by Land) over the top of the carry case label for protection. M203 CLEAR STACK SIMULATOR INST.
  • Page 74 Model 4500 Premier Dust and Opacity Monitor Fitting the Simulator The M203 Clear Stack Simulator (Part Number 703.902) is used during the Re-calibration routine when true clear stack conditions are unobtainable. The Simulator should be fitted, as described below, when 'Clear path' is displayed by the instrument (see Re-calibration). Follow the steps below, being careful NOT to move the sliding adjusting plate on the back of the Simulator.
  • Page 75 Model 4500 Premier Dust and Opacity Monitor Check that the serial number of the instrument corresponds to the number marked on the Simulator. Offer up the Simulator and tighten the two 5mm Allen bolts as shown below. M5 Allen Bolt M5 Allen Bolt Sliding Adjusting Plate M203 Clear Stack Simulator...
  • Page 76 Model 4500 Premier Dust and Opacity Monitor On the User interface press the ENTER key and wait for the display to read '100% Point'. Opacity: Opacity: ↵ ↵ ↵ ↵ ↵ Clear Path 100% point At the Transceiver undo the 2 socket head screws and remove the Simulator. Store the Simulator in the carry case provided until required for Re-calibration.

  • Page 77: B3-6 M203 Clear Stack Simulator Calibration

    Please ensure that all optical surfaces are clean and the optical path is not obstructed before performing any calibration. If the flange to flange path length is altered (i.e. due to relocation of the instrument) contact Land customer services for instrument pathlength setup advice.
  • Page 78 Model 4500 Premier Dust and Opacity Monitor Automatic Zero Point Assembly Remove the Automatic Zero Point Assembly by undoing the two socket head screws. Fit the M203 Clear Stack Simulator as described in the previous section. At the User interface set the instrument to display negative values (see section C4-4) and then observe the measurement reading with the M203 Clear Stack Simulator still attached.
  • Page 79 Model 4500 Premier Dust and Opacity Monitor Lock the sliding adjusting plate in place. IMPORTANT The M203 Clear Stack Simulator once calibrated to an instrument should not be adjusted unless undergoing another re-calibration. Undo the 2 socket head screws and remove the Simulator. Store the Simulator in the carry case provided until required for Re-calibration.

  • Page 80: B3-7 Zero Point Reflector Adjustment

    It is mandatory for installations complying with USEPA regulations. If in any doubt about these instructions, please contact Land Customer Services Department before proceeding. Take care when handling the reflective surfaces as they can easily be scratched or made dirty.
  • Page 81 Model 4500 Premier Dust and Opacity Monitor Repeat the Re-calibration procedure (see section B3-3). Display the parameter 'B' on the Parameters menu (see section B3-6). The 'B' value should now be within the range 0.95 to 1.05. The zero point reflector is ready for normal use.
  • Page 82 Model 4500 Premier Dust and Opacity Monitor Zero Point Reflector, Aperture Plate and Grating Installation A range of apertures and gratings for the Zero Point Reflector are provided with the instrument. CAUTION Do not attempt to ROTATE the zero point reflector by hand. The precision gearbox will be irreparably damaged.
  • Page 83 Model 4500 Premier Dust and Opacity Monitor Installing an Aperture Plate and Grating Zero Point Reflector Variable Aperture Assembly Key. Zero Point Reflector Holder Grating Aperture Plate Reflector Plate 3mm socket head screws Undo the three M3 socket head screws (5) using a 2.5mm hexagonal (Allen) key and remove the Reflector Plate, Aperture Plate and Grating.

  • Page 84: B3-8 Upscale Span Filter Adjustment

    Model 4500 Premier Dust and Opacity Monitor B3-8 Upscale Span Filter Adjustment U.S. Legislation requires that the instrument is periodically checked using an Upscale Calibration Value that is 150% to 190% of the applicable opacity standard. This is achieved using an Automatic Span Filter.
  • Page 85 Model 4500 Premier Dust and Opacity Monitor Undo the 2 flat head screws (accessible from underneath the Transceiver) holding the Micro Processor Board in place (NOTE:- These screws are captive). Disconnect the Micro Board from the Main P.C.B. Remove the Micro Processor Board. CAUTION Do not attempt to ROTATE the span filter by hand.
  • Page 86 Model 4500 Premier Dust and Opacity Monitor Installing a Grating Span Filter Key. Span Filter Holder Grating M3 socket head screws Undo the three M3 socket head screws (3) using a 2.5 mm socket key (Allen Key) and remove the old grating. Locate the new grating (see the Span Filter Gratings table in Appendix A).

  • Page 87: C1 Theory Of Operation And Application

    The wavelength response of an opacity monitor must mimic that of the human eye. An instrument must have a nearly photopic response. The Land Model 4500 Premier uses a high-intensity green LED light source to achieve this.

  • Page 88: C1-2 Beer-Lambert's Law

    Model 4500 Premier Dust and Opacity Monitor C1-2 Beer-Lambert’s Law The mathematical relationship between the light transmitted by a medium and the quantity of pollutant present is known as the Beer-Lambert Law and may be written; τ = I = e -acL τ...

  • Page 89: Optical Pathlength Ratio (Oplr)

    It should also be pointed out at this time that the Land Model 4500 Premier Dust and Opacity Monitor is a double pass instrument. This means that the light beam crosses the medium twice and hence experiences twice the amount of absorption as illustrated below.
  • Page 90 Model 4500 Premier Dust and Opacity Monitor We can use the previous equations to calculate the opacity at the stack exit, if we define the pathlength correction factor (PLCF); PLCF = L where: = the exit pathlength = the measurement pathlength PLCF OPLR = -OD ×...

  • Page 91: Examples Of Different Optical Pathlength Ratios (Oplr)

    Model 4500 Premier Dust and Opacity Monitor C1-4 Examples of Different Optical Pathlength Ratios (OPLR) Straight stack. Measurement pathlength and exit pathlength are equal. PLCF = 1.00, OPLR = 0.50 Example 1 Straight stack, monitor on narrow duct. Measurement pathlength is less than exit pathlength. PLCF >...

  • Page 92: C2 Requirements For Environmental Legislation

    Model 4500 Premier Dust and Opacity Monitor Requirements for Environmental Legislation The Model 4500 Premier meets or exceeds the requirements of U.S. 40CR60 AppB PS1, CPS-0001 and ASTM Standard Practice D6216.

  • Page 93: C3 Physical Principles

    Physical Principles C3-1 General Description The Land Instruments International Model 4500 Premier Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam through flue gases. An internal microprocessor calculates opacity, dust density and other parameters. The instrument comprises the following parts: The Transceiver which contains all of the optical and electro–optic components;...

  • Page 94: C3-2 Principle Of Operation

    Model 4500 Premier Dust and Opacity Monitor C3-2 Principle of Operation The Land Model 4500 Premier is the most sensitive opacity monitor available. It can accurately measure stack opacity below 1%. The Model 4500 Premier has been developed from the highly successful Land Model MkII , which already has a well-deserved reputation for reliability and accuracy.
  • Page 95 Model 4500 Premier Dust and Opacity Monitor light originally reflected by the beamsplitter (3) falls on the concave mirror (8) which focuses it onto reference detector (7). The opacity value can be calculated from the ratio of the signals on the two detectors.

  • Page 96: C4 User Interface

    Model 4500 Premier Dust and Opacity Monitor User Interface C4-1 Operational Structure The operational structure of the Model 4500 Premier is basically made up of a ‘MENU SPINE’ containing five menus ‘FAULTS’, ‘CALIBRATION’, ‘SETUP’, ‘DISPLAY’ and ‘PARAMETERS’. Scroll through the ↵...

  • Page 97: C4-2 Faults Screens

    Model 4500 Premier Dust and Opacity Monitor C4-2 Faults Screens FAULTS FAULTS On selection of FAULTS from the menu spine, press the ‘ENTER’ (↵ ↵ ↵ ↵ ↵ ) key. ↵ ↵ ↵ ↵ ↵ No Faults Detected Opacity: If no faults are detected by the software, the display will show ' Faults:0' Faults: and the user may return to the menu spine by pressing the EXIT key.

  • Page 98: C4-3 Calibration Screens

    Model 4500 Premier Dust and Opacity Monitor C4-3 Calibration Screens The instrument is checked and calibrated using the calibration menu. On selection of CALIBRATION ENTER' (↵ ↵ ↵ ↵ ↵ ) key. The calibration menu contains seven sub menus: ‘ on the menu spine, press the Calibration Check Manual Calibration...
  • Page 99 Model 4500 Premier Dust and Opacity Monitor CALIBRATION CHECK (CAL CHECK) Opacity: Cal. Check: ENTER' (↵ ↵ ↵ ↵ ↵ ) key. The monitors will perform a ‘ On selection press the zero and span check. This will take approximately three minutes to complete.
  • Page 100 Model 4500 Premier Dust and Opacity Monitor ISOKINETIC CALIBRATION Opacity: Isokinetic Cal This procedure is done in conjunction with an isokinetic sample or samples, being taken at the same time and under the same conditions as ↵ ↵ ↵ ↵ ↵ the measurements being taken by the Model 4500 Premier.
  • Page 101 Model 4500 Premier Dust and Opacity Monitor Calculate (Isokinetic Calibration sub-menu) Isokinetic Cal Calculate: Using the ↑ or ↓ keys when 'Acquire' is displayed to access the ‘Calculate’ sub-menu. Press the ‘ENTER' (↵ ↵ ↵ ↵ ↵ ) key to select 'Meas. Dust x.xx’ (notice ↵...
  • Page 102 Model 4500 Premier Dust and Opacity Monitor MANUAL CALIBRATION (MANUAL CAL) Opacity Manual Cal. This sequence is not recommended to be followed by the user. The manual cal sequence requires values to be entered manually. Re-calibrate is a more accurate operation. This provision is of more practical use to a service engineer.
  • Page 103 Model 4500 Premier Dust and Opacity Monitor Interval Cal. Setup Interval: ENTER' (↵ ↵ ↵ ↵ ↵ ) key (notice the ‘ On selection of ‘Interval xxh’ press the underlined ‘x’). Use the ↑ and ↓ keys to select the time interval (in hours) ↵...

  • Page 104: Setup Screens

    Model 4500 Premier Dust and Opacity Monitor C4-4 Setup Screens The instrument is made ready for operation using the ‘Setup’ menu. On selection of ‘Setup’ on the ENTER' (↵ ↵ ↵ ↵ ↵ ) key. The setup menu contains four sub-menus: ‘...
  • Page 105 Model 4500 Premier Dust and Opacity Monitor Setup Output Screens (Outputs) Two signal outputs are available to the user and are setup using the ‘Output 1’ and ‘Output 2’ sub- menus respectively. The time period used for block averaging may be set independently for each output using the ‘Average 1’...
  • Page 106 Model 4500 Premier Dust and Opacity Monitor SETUP OUTPUTS (OUTPUT 1) Outputs Output 1 The first customer output is set from this menu. On selection press the ENTER' (↵ ↵ ↵ ↵ ↵ ) key. There are now two further options to set for each of ‘...
  • Page 107 Model 4500 Premier Dust and Opacity Monitor Dust. Output 1 Dust ENTER' (↵ ↵ ↵ ↵ ↵ ) key (notice no underlining). ‘ On selecting ‘Dust’ press the Two options are available, ‘Range’ (Dust range is in mg/m ) and ‘During ↑↓...
  • Page 108 Model 4500 Premier Dust and Opacity Monitor Constant Current Output 1 Output 1 Constant Current is normally used to calibrate the users data acquisition system. ↑↓ ENTER' (↵ ↵ ↵ ↵ ↵ ) key (notice no underlining). ‘ On selecting ‘Constant’ press the Output 1 Two options are available, ‘Constant’...
  • Page 109 Model 4500 Premier Dust and Opacity Monitor Calibration Drift (Cal. Drift) Output 1 Cal. Drift ENTER' (↵ ↵ ↵ ↵ ↵ ) key (notice no underlining). ‘ On selecting ‘Cal. Drift’ press the Two options are available, ‘Range’ and ‘During Cal’. These two options ↑↓...
  • Page 110 Model 4500 Premier Dust and Opacity Monitor Optical Density (O.D.) Output 1 O.D. ENTER' (↵ ↵ ↵ ↵ ↵ ) key (notice no underlining). ‘ On selecting ‘O.D.’ press the Two options are available, ‘Range’ (O.D. range is in units of Optical ↑↓...
  • Page 111 Model 4500 Premier Dust and Opacity Monitor SETUP OUTPUTS (AVERAGING 1) Outputs Output 1 On selection of ‘Averaging 1’ from the ‘Output 1’ menu, as described ENTER' (↵ ↵ ↵ ↵ ↵ ) key. The display changes to ‘ previously, press the ‘Averaging: Off’...
  • Page 112 Model 4500 Premier Dust and Opacity Monitor Setup Alarms (Alarms) Two alarm facilities are available to the user, each may be programmed to trip at specified levels with a 0 to 30 seconds delay for Optical Density, Opacity or Dust as illustrated below. SETUP AL1 Type: O.D.
  • Page 113 Model 4500 Premier Dust and Opacity Monitor SETUP ALARMS (ALARMS) SETUP Alarms ENTER' (↵ ↵ ↵ ↵ ↵ ) key and ‘Alarm 1’ is ‘ On selecting ‘Alarms’ press the displayed. Press the ↑ or ↓ keys to scroll through the two alarm facilities. ↵...
  • Page 114 Model 4500 Premier Dust and Opacity Monitor SETUP MISCELLANEOUS (MISCELLANEOUS) ENTER' (↵ ↵ ↵ ↵ ↵ ) key. The miscellaneous menu gives access to a number of ‘ On selection press the additional functions: Align Dust Gain Show -ve Display Dust Offset O/P1 range OP 0 limit...
  • Page 115 Model 4500 Premier Dust and Opacity Monitor Alignment of Instrument (Align) Signal: xxx.x ENTER' (↵ ↵ ↵ ↵ ↵ ) key to display the alignment value. ‘ On selection press the Align the instrument along its optical axis (see Using The Instrument for the First Time section) to display the maximum value.
  • Page 116 ‘ the option (notice no underlined character). It is now possible to scroll through the ‘Miscellaneous sub-menu’ by pressing the ↑ ↓ keys. Do not change this value without authorisation from Land Instruments International. Show negative values (show -ve) Show -ve: ENTER' (↵...
  • Page 117 SETUP SERVICE (SERVICE) This menu only permits access with an entry code and is reserved for the use of LAND service personnel. Press the ↑ or ↓ keys to scroll through the Setup menu or press the EXIT key to return to the menu spine.

  • Page 118: Display Screens

    Model 4500 Premier Dust and Opacity Monitor C4-5 Display Screens DISPLAY (DISPLAY) ENTER' (↵ ↵ ↵ ↵ ↵ ) key. Two Display menus ‘Top Line’ ‘ On selection of ‘Display’ on the menu spine press the and ‘Bottom Line’ can be scrolled through by pressing the ↑ or ↓ keys. The display is customised by selecting the required display (see below) for both the top line and the bottom line of the display.
  • Page 119 Model 4500 Premier Dust and Opacity Monitor Setting Bottom Line Display ENTER' (↵ ↵ ↵ ↵ ↵ ) key. Press the ← or → keys to scroll through the ‘ On selection of ‘Bottom Line’ press the ENTER' (↵ ↵ ↵ ↵ ↵ ) key again to set the option selected. The display ‘...

  • Page 120: C4-6 Parameter Screens

    Model 4500 Premier Dust and Opacity Monitor C4-6 Parameter Screens PARAMETERS PARAMETERS This menu contains the Model 4500 Premier internal parameters and is used as a general software dump with updated readings. It is not normally ↵ ↵ ↵ ↵ ↵ intended for customer use, but may be useful for diagnosing particular problems.

  • Page 121: C5 System Specification

    Model 4500 Premier Dust and Opacity Monitor System Specification C5-1 4500 Premier Dust and Opacity Monitor Measuring Technique: Double pass/path transmissometry Operating Wavelength: 520 ± 20 nm Light Source: High Intensity LED Range: Opacity 0 – 10 % to 0 – 100 % Optical Density 0 –...
  • Page 122 Model 4500 Premier Dust and Opacity Monitor Environmental Operating temperature: -20 to 55 C / -4 to 131 (-40 C / -40 F with optional heater) Maximum Flue Gas temperature: 600 C / 1112 Maximum Flange Temp: C / 392 Environmental rating: IP66 / NEMA4X Compliance...
  • Page 123 Model 4500 Premier Dust and Opacity Monitor Termination Box Modbus Interface: RS232 or RS485 Multi-drop Opacity, Dust, Optical Density, Status, Averaging and Range Information available Calibration sequence trigger Analogue Outputs : Two 4-20mA current loops, fully isolated 50 V d.c. Independently configurable as: Opacity, Dust, Optical Density or Calibration Drift Relay Outputs:...

  • Page 124: C6 Testing And Checking

    Testing and Checking C6-1 Identifying Faults The Land Model 4500 Premier Dust/Opacity Monitor has been designed to allow the user to troubleshoot a number of possible problems and faults. If a fault condition occurs, the system OK LED on the transmissometer will not be illuminated and the System OK relay will reset to Fault condition.
  • Page 125 Calibration error: Check calibration. Re-calibrate if necessary. IMPORTANT Whenever the Land Service Department is contacted regarding problems with an instrument, please have available information on the instrument type and serial number. This will enable the department to respond more accurately and efficiently.

  • Page 126: Maintenance

    Model 4500 Premier Dust and Opacity Monitor C6-2 Maintenance The Land Instruments International Model 4500 Premier has been designed for a minimal amount of routine maintenance . To ensure a maximum monitor lifetime however, the following maintenance schedule has been developed. Remember that the air purge system should always be left on, even if the boiler is off, to prevent any contamination of the optics.
  • Page 127 4500 Premier. The time taken for significant contamination to occur depends very much on the nature of the installation, but in a typical situation it should be sufficient to clean the optics every 90 days. Three optical components should be cleaned, using the lens cloth supplied by Land Instruments International. CAUTION Always use a lint free lens cloth to clean the optical surfaces.
  • Page 128 The Model 4500 Premier has been configured and tested for the pathlength specified at the time of purchase. Changing its pathlength will alter its calibration and may invalidate any certificate of compliance. Do not change the installation pathlength without authorization from Land Instruments International. Tools required 2.5 mm hex (Allen) key...
  • Page 129 Model 4500 Premier Dust and Opacity Monitor Focus Table NO SHUTTER LOWER UPPER LOWER UPPER SPACER Screw length Retro 0.97 1.18 704.527 1.18 1.46 704.528 1.46 1.85 704.528 1.85 2.46 704.528 2.46 3.51 704.530 3.51 4.50 704.531 4.50 5.77 704.531 5.77 7.00 704.532...

  • Page 130: Replacement Parts And Consumables

    Model 4500 Premier Dust and Opacity Monitor C6-3 Replacement Parts and Consumables Consumables Description ................Part Number Lens cloth................... 320.804 Flange Sealing Ring ..............701.981 Spares Parts Spherical Washers ..............702.749 Spring washer ................318.284 M12 Locknuts ................315.040 Flange Stud ................702.755 Microprocessor Module PCB .............

  • Page 131: Lens Cloth

    Model 4500 Premier Dust and Opacity Monitor Identifying Spare Parts Flange-to-Flange Path Length Without Failsafe Shutter With Failsafe Shutter metres inches metres inches Reflector Assembly From To From To From To From To 704.527 0.97 1.18 0.74 0.94 704.528 1.18 2.46 0.94 2.22...

  • Page 132: Microprocessor Module Pcb

    Model 4500 Premier Dust and Opacity Monitor Microprocessor Module PCB Signal Processor PCB (Part Number 702.762) (Part Number 702.684) Reference Detector PCB Measurement Detector PCB (Part Number 702.648) (Part Number 702.645) Control Panel PCB Flood LED PCB Source LED PCB (Part Number 704.228) (Part Number 702.691) (Part Number 702.688)

  • Page 133: Zero Calibration Motor Assembly

    Model 4500 Premier Dust and Opacity Monitor Air Purge Diffuser Main Lens Assembly Zero Calibration Assembly (Part Number 702.781) (Part Number 700.911) (Part Number 702.778) Zero calibration micro switch (Part Number 702.832) Zero calibration motor assembly (Part Number 702.833) Termination Box PCB (Part Number 704.229) Transmissometer Housing incl.

  • Page 134: C7 Configuration Record Sheet

    Model 4500 Premier Dust and Opacity Monitor Configuration Record Sheet Please complete the Configuration Record Sheet. General Information Instrument Serial Number Date of Purchase Technical Information Pathlength Service History Date Action Repair History Date Action Part Replaced Part No.
  • Page 135 Model 4500 Premier Dust / Opacity Monitor (Appendix) Part No 770.084...

  • Page 137: Appendix

    Appendix Model 4500 Premier Dust and Opacity Monitor Appendix A Aperture and Grating Selection Tables AppA-1 Automatic Zero Point Reflector Aperture and Grating Selection Aperture B Value Plate Grating A Grating 1 Grating 2 Grating 3 Grating 4 Grating 5 1.69 1.30 1.00...

  • Page 138: Appendix B Low Temperature Termination Box

    Model 4500 Premier Dust and Opacity Monitor Appendix Appendix B Low Temperature Termination Box AppB-1 Termination Box Heater Unit Thermostatically Controlled Heated Local Control Unit Brief Description A 40W heater pad is pre-wired behind the PCB and controlled via a thermostat switch located on the underside of the main PCB.

  • Page 139: Standard Terms Of Warranty

    Combustion & Environmental Division STANDARD TERMS OF WARRANTY Land Instruments International warrant all products of our own manufacture to be within specified limits of calibration, if any, when despatched from our works. Also that they are free from defects in material and workmanship for normal use and service when used for their intended purpose within the limits of our specification.

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