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Model 4400i
MODEL 4400USER GUIDEPUBLICATION NO 813263LANGUAGE: ENGLISH
Q U A L I T Y C U S T O M E R S O L U T I O N S
Health and Safety InformationRead all of the instructions in this booklet - including all the WARNINGS and CAUTIONS - before using this product. If there is any instruction which you do not understand, DO NOT USE THE PRODUCT.
Safety SignsWARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or personal injury.
CAUTIONIndicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to the user or users, or result in damage to the product or to property.
NOTEIndicates a potentially hazardous situation which, if not avoided, could result in damage or loss of data.
Signs and Symbols used on equipment and Documentation
Caution, risk of electric shock.
Caution, attention to possibility of risk of damage to the product, process or surroundings. Refer to instruction manual.
Caution, hot surface.
Protective Conductor Terminal.
Observe precautions for handling electrostatic discharge sensitive devices.
Equipment OperationUse of this instrument in a manner not specified by AMETEK Land may be hazardous. Read and understand the user documentation supplied before installing and operating the equipment.The safety of any system incorporating this equipment is the responsibility of the assembler.
Protective Clothing, Face and Eye ProtectionIt is possible that this equipment is to be installed on, or near to, machinery or equipment operating at high temperatures and high pressures. Suitable protective clothing, along with face and eye protection must be worn. Refer to the health and safety guidelines for the machinery/equipment before installing this product. If in doubt, contact AMETEK Land.
Electrical Power SupplyBefore 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. If in doubt, contact AMETEK Land.
StorageThe instrument should be stored in its packaging, in a dry sheltered area. The maximum storage temperature is 10 °C (18 °F) higher than the maximum operating temperature.The minimum storage temperature is 10 °C (18 °F) lower than the minimum operating temperature.Refer to the Technical Specification for details of the operating temperature limits.UnpackingCheck all packages for external signs of damage. Check the contents against the packing note.
Lifting InstructionsWhere items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the Technical Specification for weights. All lifting should be carried out in accordance with local and national regulations.
IMPORTANT INFORMATION - PLEASE READ Contact UsUK - DronfieldLand Instruments InternationalTel: +44 (0) 1246 417691
USA - PittsburghAMETEK Land, Inc.Tel: +1 412 826 4444
ChinaAMETEK Land China Service Tel: +86 21 5868 5111 ext 122
IndiaAMETEK Land India ServiceTel: +91 - 80 67823240
Email: land.enquiry@ametek.com
Web: www.ametek-land.com
For further details on all AMETEK Land offices, distributors and representatives, please visit our website.
Return of Damaged GoodsIMPORTANT If any item has been damaged in transit, this should be reported to the carrier and to the supplier immediately. Damage caused in transit is the responsibility of the carrier not the supplier.DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save the packing with the damaged article for inspection by the carrier.
Return of Goods for RepairIf you need to return goods for repair please contact our Customer Service Department for details of the correct returns procedure.Any item returned to AMETEK Land should be adequately packaged to prevent damage during transit.You must include a written report of the problem together with your own name and contact information, address, telephone number, email address etc.
Design and Manufacturing StandardsThe Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for the design, manufacture and on-site servicing of combustion, environmental monitoring and non-contact temperature measuring instrumentation.
Registered ISO 9001 Management System approvals apply in the USA.
UK Calibration Laboratory: UKAS 0034.
USA Calibration Laboratory: ANAB Accredited ISO/IEC 17025.
National Accreditation Board for Testing and Calibration Laboratories approvals apply in India.
Operation of radio transmitters, telephones or other electrical/electronic devices in close proximity to the equipment while the enclosure doors of the instrument or its peripherals are open, may cause interference and possible failure where the radiated emissions exceed the EMC directive. The protection provided by this product may be invalidated if alterations or additions are made to the structural, electrical, mechanical, pneumatic, software or firmware components of this system. Such changes may also invalidate the standard terms of warranty.
CopyrightThis manual is provided as an aid to owners of AMETEK Land’s products and contains information proprietary to AMETEK Land. This manual may not, in whole or part, be copied, or reproduced without the expressed written consent of AMETEK Land.
Copyright © 2018 Land Instruments International.
MARCOM0311, Issue 10, 13 June 2018
Health and Safety InformationRead all of the instructions in this booklet - including all the WARNINGS and CAUTIONS - before using this product. If there is any instruction which you do not understand, DO NOT USE THE PRODUCT.
Safety SignsWARNINGIndicates a potentially hazardous situation which, if not avoided, could result in death or personal injury.
CAUTIONIndicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to the user or users, or result in damage to the product or to property.
NOTEIndicates a potentially hazardous situation which, if not avoided, could result in damage or loss of data.
Signs and Symbols used on equipment and Documentation
Caution, risk of electric shock.
Caution, attention to possibility of risk of damage to the product, process or surroundings. Refer to instruction manual.
Caution, hot surface.
Protective Conductor Terminal.
Observe precautions for handling electrostatic discharge sensitive devices.
Equipment OperationUse of this instrument in a manner not specified by AMETEK Land may be hazardous. Read and understand the user documentation supplied before installing and operating the equipment.The safety of any system incorporating this equipment is the responsibility of the assembler.
Protective Clothing, Face and Eye ProtectionIt is possible that this equipment is to be installed on, or near to, machinery or equipment operating at high temperatures and high pressures. Suitable protective clothing, along with face and eye protection must be worn. Refer to the health and safety guidelines for the machinery/equipment before installing this product. If in doubt, contact AMETEK Land.
Electrical Power SupplyBefore 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. If in doubt, contact AMETEK Land.
StorageThe instrument should be stored in its packaging, in a dry sheltered area. The maximum storage temperature is 10 °C (18 °F) higher than the maximum operating temperature.The minimum storage temperature is 10 °C (18 °F) lower than the minimum operating temperature.Refer to the Technical Specification for details of the operating temperature limits.UnpackingCheck all packages for external signs of damage. Check the contents against the packing note.
Lifting InstructionsWhere items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the Technical Specification for weights. All lifting should be carried out in accordance with local and national regulations.
IMPORTANT INFORMATION - PLEASE READ Contact UsUK - DronfieldLand Instruments InternationalTel: +44 (0) 1246 417691
USA - PittsburghAMETEK Land, Inc.Tel: +1 412 826 4444
ChinaAMETEK Land China Service Tel: +86 21 5868 5111 ext 122
IndiaAMETEK Land India ServiceTel: +91 - 80 67823240
Email: land.enquiry@ametek.com
Web: www.ametek-land.com
For further details on all AMETEK Land offices, distributors and representatives, please visit our website.
Return of Damaged GoodsIMPORTANT If any item has been damaged in transit, this should be reported to the carrier and to the supplier immediately. Damage caused in transit is the responsibility of the carrier not the supplier.DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save the packing with the damaged article for inspection by the carrier.
Return of Goods for RepairIf you need to return goods for repair please contact our Customer Service Department for details of the correct returns procedure.Any item returned to AMETEK Land should be adequately packaged to prevent damage during transit.You must include a written report of the problem together with your own name and contact information, address, telephone number, email address etc.
Design and Manufacturing StandardsThe Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for the design, manufacture and on-site servicing of combustion, environmental monitoring and non-contact temperature measuring instrumentation.
Registered ISO 9001 Management System approvals apply in the USA.
UK Calibration Laboratory: UKAS 0034.
USA Calibration Laboratory: ANAB Accredited ISO/IEC 17025.
National Accreditation Board for Testing and Calibration Laboratories approvals apply in India.
Operation of radio transmitters, telephones or other electrical/electronic devices in close proximity to the equipment while the enclosure doors of the instrument or its peripherals are open, may cause interference and possible failure where the radiated emissions exceed the EMC directive. The protection provided by this product may be invalidated if alterations or additions are made to the structural, electrical, mechanical, pneumatic, software or firmware components of this system. Such changes may also invalidate the standard terms of warranty.
CopyrightThis manual is provided as an aid to owners of AMETEK Land’s products and contains information proprietary to AMETEK Land. This manual may not, in whole or part, be copied, or reproduced without the expressed written consent of AMETEK Land.
Copyright © 2018 Land Instruments International.
MARCOM0311, Issue 10, 13 June 2018
Opacity and Dust Monitor
User GuidePreface
Model 4400
Blank
Preface
Opacity and Dust Monitor
User Guide
Model 4400
Contents
A Introduction
A1 General Description A-1A2 Installation Diagram A-3A3 Installation Instructions A-4A4 Auxiliary Power Supply (APS42) A-18
B Getting Started
B1 The User Interface B-1B2 Function Keys B-2B3 Glossary of Terms B-5B4 Using the Instrument for the First Time B-6B5 Periodic Modes of Operation B-16
C Theory of Operation and Application
C1 General Outline C-1C2 Beer-Lambert’s Law C-2C3 Physical Principles C-3
D SystemSpecification
D1 4400 Dust and Opacity Monitor D-1D2 Auxiliary Power Supply (APS42) D-3
E Maintenance
E1 Identifying Faults E-1E2 Routine Maintenance E-3E3 Removing the Transceiver Cover E-5E4 Replacement Parts and Consumables E-6
F Changing the Installation Pathlength on a Model 4400
E1 Set the correct focus F-1E2 Align and Calibrate the Model 4400 F-1E3 Focus Table F-2
G ConfigurationRecordSheet G-1
INTRODUCTION
A
A - 1
Opacity and Dust Monitor
User Guide
Model 4400
A Introduction
A1 General DescriptionThe Land Instruments International Model 4400 Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam throughfluegases.
Aninternalmicroprocessorcalculatesdustdensityandotherparameters.The Model 4400 is designed for continuous operation in all weather conditions.Maintenancerequirementsareminimal.Transceiver Containing all of the major electronic and electro–optic
components.Retro-Reflector Containingacornercubereflector.Air Purge System A continuous supply of purge air is essential to prevent
dustandcorrosivegasesfromaffectingtheopticalsystem.Singleanddualelectricblowersorcompressed-air driven devices are available to suit individual site requirements.Automaticfail–safeshutterscanalsobefittedfortemporaryprotectionintheeventofapurgeairfailure.
Opacity and Dust Monitor
User GuideA - 2
Model 4400
Power Supply
The Model 4400 operates from a 24 V d.c. supply.
Analogue OutputThe Model 4400 Dust and Opacity Monitor has a current loop output that may be set to one of the four functions below: Opacity Dust Constant Current Optical Density
Relay OutputsLocated on the key panel of the 4400 are three LEDs which light to indicate the operation of the following relay outputs: SYSTEM OK CALIBRATION ALARMS
Computer Interface OperationThe Model 4400 Dust and Opacity Monitor may be connected to a computer ordataacquisitionsystemviaitsRS485Modbusinterface.
Auxiliary Power Supply (APS42)Optionalexternalmains-poweredunittoprovide24Vd.c.power.Alsoprovides screw terminal contacts for customer connections and power distributiontooptionalfail-safeshutters.
A - 3
Opacity and Dust Monitor
User Guide
Model 4400
A2 Installation DiagramTypical Model 4400 Dust Opacity Monitoring System, showing all components installed.
Fail-Safe Shutter(Optional)
Fail-Safe Shutter(Optional)
Retro-ReflectorTransceiver
Air Purge BlowerAir Purge Blower
APS42
Mains Powerfor Blower
Mains Powerfor Blower
Mounting Flanges
Opacity and Dust Monitor
User GuideA - 4
Model 4400
A3 Installation Instructions
CAUTION
If the blower is not supplied through an APS (as described in Section A4), an external isolator, incorporating over-current protection, must be fittedtotheblowersupply.
CAUTION
The purge air supply must be connected and working before the TransceiverandtheRetro-Reflectorareinstalled.
A3.1 Installation Checklist1) Selecttheinstallationlocation.2) Installthemountingflanges.3) InstalltheAirBlowerUnit(s)forthepurgeairsupply.ConsulttheAir
BlowerUnitInstructionManualforfulldetails.4) An external circuit breaker, incorporating over-current protection or a
powerisolatorandfusemustbefittedtotheblowersupply.5) Routeallsignalandpowercables.6) ConnectthepowersupplytotheAirBlowerUnit(s).7) Connect the electrical power supply and signals to the instruments,
using the 5 m(16ft)pre-terminatedcablessupplied.8) Poweruptheairpurgesystem.9) InstalltheTransceiverandRetro-reflector.Remembertoconnectthe
purge air supply from the Air Blower Unit(s) before mounting them on theflanges.
10) Poweruptheinstrumentandcalibrateit.
A - 5
Opacity and Dust Monitor
User Guide
Model 4400
A3.2SelectinganInstallationLocationThe location of the mounting flanges may be affected by the type of Air Blower Unit(s) to be used. Please refer to the Air Blower Unit manual.1) For new plants, the location of the Transmissometer should be planned
duringthedesignstages.Forexistingplants,itiscriticalthatthebestpossiblelocationbeselected.TheTransmissometershouldbemountedso that it measures a representative concentration of dust across the stackorductdiameter.
2) If the monitor is to be used for US regulatory compliance the location shouldbedeterminedbytheEPAinstallationspecificationsdetailedin40CFR60,AppendixB,PerformanceSpecification1,oralocationapprovedbytheappropriateagency.InEuropethelocationshouldthedeterminedinaccordancewithEN15259.
3) At the installation location, there should be as much negative pressure aspossible,forexample,astackupdraft.
4) The mounting area must have a safe walkway: if necessary, a sufficientlylargeandaccessibleplatformshouldbeconstructed.
5) The ambient temperature at the mounting location must remain between-40°Cand+55°C(-4°Fand131°F).Ifnecessary,heating,ventilation, or a sun shield should be used to ensure this temperature rangeisnotexceeded.
6) If the duct walls are too thin to support the weight of the instrument, additionalreinforcementwillberequired.
7) ThemountingflangesmustbepositionedsuchthattheTransceiverandRetro-Reflectorfaceeachotheracrossthecentreofthestackorduct.Since most applications involve a vertical stack, the axis common to bothflangesmustbelevelandperpendiculartothedirectionofgasflow.
Mountingflangeforadjustment
Access platform
Stack
Opacity and Dust Monitor
User GuideA - 6
Model 4400
A3.4 Installing the Mounting FlangesTheModel4400issuppliedwithtwomountingflangeswithstand-offs(standpipes)usedtomounttheTransmissometerontothestackorduct.1) Eachstandpipeis128mm(5.04in)long.2) Accuratelymarkthecentreofeachmountingflangeonthestackand
punchalocatingmarkthroughthelinerontotheinnerstackplating.3) On both sides of the stack, cut a hole from the liner large enough to
allowweldingofthemountingflangetothestack.4) Where the Transceiver will be installed, cut a hole through the stack at
thepunchedlocationmark.5) WheretheRetro-Reflectorwillbeinstalled,makea6mmto12mm
diameterpilothole(0.25into0.50in)
A3.3 Maintaining the path length during installationTheinstallationpathlengthisdefinedasthedistancebetweentheouterfacesofthemountingflangesofthetransceiverandretroreflector.Thisissomewhatgreaterthanthestackflange-to-flangepathlength,toallowforopticalalignment.Thelengthofaccessoriessuchasspoolpiecesorfail-safe shutters also increases the installation path length relative to the stack flange-to-flangepathlength.The installation path length must be specified at the time of order and the instrument is factory set for this path length.TheinstallationpathlengthisindicatedonthebackoftheTransceiver.Duringtheweldingandalignmentprocedurestheflange-to-flangemeasurement path must not change by more than ±1%, otherwise the accuracyofthemeasurementreadingsmaybeaffected.
Flangetoflangepathlength
Transceiver Retro-reflector
A - 7
Opacity and Dust Monitor
User Guide
Model 4400
6) PositiontheTransceivermountingflangewiththe“TOP”labelinthe12o’clockpositionandtackweldthemountingflangeinplace.
Accurate positioning of the flange at this stage is critical to the operation of the instrument. If the flange is not parallel to the stack wall it will be impossible to align the instrument correctly.
7) CutaholearoundtheRetro-Reflectorpilothole,largeenoughtoalloweventualweldingoftheoutsideoftheflangestubtothestackwall.Themountingflangeplatemustbeparalleltothestackwall.
8) Ifthemeasuringpathisshort(under2m/6.5ft)andeasilyaccessibletheflangescanbealignedusingastraightpieceoftube.a) Slidethetubethroughbothflanges.Ensuringthespecifiedflange-
to-flangemeasuringpathismaintainedtowithin±1%.b) TackweldtheRetro-Reflectormountingflangeinplace.c) Make any necessary adjustments to the Transceiver mounting
flangetoensurealignmentbetweenthetwoflangesismaintained.Weldtheflangepermanentlyinplace.
d) MakeanynecessaryadjustmentsandweldtheRetro-Reflectormountingflangepermanentlyinplace.
An optical flange alignment tool (Part number 703.070) can be used to ensure the proper alignment of the flanges. Contact Land Instruments for more information.
TOP
Opacity and Dust Monitor
User GuideA - 8
Model 4400
Front view of Air Purge showing mounting holes
A3.5 Mounting Details
Air Purge Mounting HolesTheairpurgeunitmustbefixedtothemountingflange.IthasthreemountingholestoacceptthemountingstudsfromtheStandpipe.
Mounting holes
130mm(5⅛”)
A - 9
Opacity and Dust Monitor
User Guide
Model 4400
4400
Sys
tem
Ins
talla
tion
Ove
rvie
w
4400
Tran
scei
ver
4400
Retr
oref
lect
or
Fail
Saf
e Shu
tter
Retr
oref
lect
or(o
ptio
nal)
Sea
ling
Ban
d
270m
m (
10.6
3in)
210m
m(8
.25i
n)
Blo
wer
Hos
e [I
D 3
8.1
mm
(1.
5in)
]La
nd P
art
Nº
306.
046
Blo
wer
Hos
e [I
D 3
8.1
mm
(1.
5in)
]La
nd P
art
Nº
306.
046
Pla
te M
oun
ted
Blo
wer
For
mou
ntin
g de
tails
see
draw
ing
A3
740.
051
She
et3
Pla
te M
oun
ted
Blo
wer
For
mou
ntin
g de
tails
see
draw
ing
A3
740.
051
She
et3
Sta
ndar
d Sta
nd P
ipe
Land
Par
t N
º 70
2.79
0Sea
ling
Ban
d
Fail
Saf
e Shu
tter
Retr
oref
lect
or(o
ptio
nal)
210m
m(8
.25i
n)
280m
m(1
1.0i
n)44
6mm
(17
.56i
n)
Flu
e G
as S
trea
m
Cus
tom
er c
onne
ctio
n bo
x m
ust
be m
ount
edw
ithin
5m
(15
ft)
of t
rans
ceiv
er
Blo
wer
Hos
e [I
D 3
8.1
mm
(1.
5in)
]La
nd P
art
Nº
306.
046
Set
of
3 C
onn
ecti
on C
able
sFo
r co
nnec
tions
see
dra
win
g74
0.05
8 She
et3
Not
es1)
Wel
d st
andp
ipes
into
pla
ce.
Not
e th
at
tube
s m
ust
be c
o-ax
ial &
alig
ned
±1.
0°.
2) S
lide
seal
ing
band
ove
r pu
rge
flang
e an
d le
ave
loos
e on
inst
rum
ent
purg
e.3)
Rem
ove
nuts
& s
pher
ical
was
hers
stu
ds,
leav
ing
disc
spr
ings
in p
lace
.4)
Fit
tran
scei
ver
asse
mbl
y on
to s
tuds
.5)
Fit
sphe
rica
l was
hers
& s
tuds
fro
m s
tep
3.6)
Tig
hten
the
nut
s un
til t
he g
ap b
etw
een
flang
es is
14m
m (
9/16
in)
all r
ound
.7)
Ins
tall
seal
ing
band
as
show
n.8)
Mou
nt R
etro
refle
ctor
ass
embl
y as
in
step
s 4
to 7
.9)
Sw
itch
on p
urge
air s
uppl
y
Opacity and Dust Monitor
User GuideA - 10
Model 4400
A3.6 Installation with a Fail-Safe Shutter (FSS)
A - 11
Opacity and Dust Monitor
User Guide
Model 4400
Installing a 4400 on existing 4500 series mountings
4400 Transceiver& Purge Assembly
4500 MkII to 4400 Adaptor FlangeAssembly (Part Nº 804248)
4400
5. NOTE: CHECK THAT EACH MOUNTING STUD HAS SIX PAIRS OF SPRING WASHERS
Opacity and Dust Monitor
User GuideA - 12
Model 4400
Theflangealignmenttoolisusedasfollows:1) Removethewashersfromthemountingflanges.Retaintheseasthey
areessentialtothecorrectinstallationoftheinstrument.2) Tackweldtheflangesinposition.3) Mounttheflangealignmenttoolasshownbelow,withthelightsource
attachedtoflange2.4) Alignflange1andwelditintoplace.5) Removethealignmenttoolandrefititwiththelightsourceattachedto
flange1.6) Alignflange2andwelditintoplace.7) Replacethewashers.SeesectionA3.9.
A3.7 Using the Flange Alignment ToolTheflangealignmenttool(partnumber703.070)consistsoftwoplateswhicharemountedontotheflanges.Oneplatesupportsalightsource,theotherasmalltelescopewithatargetinthecentre.Whentheflangesareproperlyaligned,thelightspotislocatedinthecentreofthistarget.
Light source Alignment circle
Light source
Flange 2 Flange 1
Reinforcement ifrequired
A - 13
Opacity and Dust Monitor
User Guide
Model 4400
4 3
5
3
INSTALLATION PATHLENGTH
1) Checkthedimensionscarefullybeforeinstallation.a) Allowatleast1m(3.3ft)formountingandremovalproceduresb) Allow a minimum of 200 mm (8 in) directly below the instrument for
purgeair(3)andelectricalconnections(4).c) Allowsufficientspacetothesideofeachinstrumenttoallowthe
hinges(6and7)tobeopened.d) Check the Blower Unit Manual for additional installation
requirements.2) Theairhosefittedbetweentheairblowerunit(seethediagraminsection
A2) and its two connections on the instrument (3) must not exceed 7m (23ft).
3) Theflange-to-flangepathlength(5)isfactorysetandmustnotbechanged.ItisgivenonthebackoftheTransceiver.
4) Pre-terminated 5 m power and data cables are supplied with this instrument.
A3.8 Important information for installing the transceiver and retro-reflector
446(17.56)128(5.04) 128(5.04)
235(9.25)
4400 Transceiver Standard stand pipe
LandPartNº703.020
4400 Retroreflector
MIN
IMU
M CLEARAN
CE REQU
IRED
327.0 (12.87’’)
R280
.0 (1
1.02
’’)
MINIMUMSWINGRADIUS
MINIMUM SWING RADIUS
MIN
IMU
M
CLEA
RAN
CE
REQ
UIR
ED
151.
5 (5
.97’
’)
R185
.0 (7.
28’’)76
Opacity and Dust Monitor
User GuideA - 14
Model 4400
4) PlacearubbersealingbandoverthemountingflangesfortheTransceiverandRetro-Reflector.Itcannotbefittedaftertheinstrumentismountedontheflange.
5) Remove the three M10 nuts (4) and dome washers (2) from the mountingflange,andlocatetheTransceiverontothestuds(3).
6) Replace the Nyloc nuts (4) and dome washers (2) and tighten them, compressing the spring washers (5), until there is a gap of 8 mm (5/16in)betweenthetwoflanges,allround.Pullthesealingband(6)intoplaceoverthegap.
7) InstalltheRetro-Reflectorfollowingthesameprocedure.
CAUTION
If the instrument is being hoisted into position, the case clips must be covered or taped closed, to prevent them from opening accidentally.
A3.9 Mounting the Transceiver and Retro-Reflector1) Ideally, the instrument should be installed when the process is not
operatingandthestackiscold.
2) The air blower unit should be operating and connected to the TransceiverandRetro-Reflectorbeforetheinstrumentismountedontotheflanges.
3) Check that each mounting stud has the correct number of spring washers (5) arranged as shown - these may have been removed if the flangealignmenttoolwasused.Thestandardflange703.020hasfourpairsofspringwashersoneachmountingstud.
123
4 5
68mm (5/16in)
Transceiver
Mountingflange
7
A - 15
Opacity and Dust Monitor
User Guide
Model 4400
A3.10 Electrical ConnectionsAll switch cabinets, distribution boxes, fuses and other components for electrical installation must be provided by the customer, as must the mains powersupplyconnections.Installationshouldbecarriedoutbyacompetentpersonandcablesshouldsatisfycurrentcarryingcapacityandvoltagerating.
Air Blower Unit ConnectionsRefertotheInstructionManualsuppliedwiththeAirBlowerUnit.
DC SupplyThe4400requiresa24Vdc2.25Asupply.Currentconsumptionis0.25Aattemperaturesabove-20°C.Currentincreasesto2.25Aatlowertemperatures,whenthecaseheatersareoperating.
Signal ConnectionsTransceiverdatacables(SeediagramsinA3.11)
Opacity and Dust Monitor
User GuideA - 16
Model 4400
A3.11 Transceiver Connections
L
NE
Connector A
LNE
RedBlueScreen
+24 V dc0 VScreen
Pin Nº Colour Function
Connector B
12345678910
RedBlueWhiteYellowGreenScreenN/CBlackBrownViolet
In Cal Relay NOAlarm Relay COMAlarm Relay NO4 to 20mA Output +4 to 20mA Output -ScreenN/CIn Cal Relay COMAlarm Relay NCIn Cal Relay NC
Pin Nº Colour Function
Connector C
12345678910
ScreenN/CRedBlueGreenYellowN/CN/CWhiteBlack
ScreenN/CSys OK Relay COMSys OK Relay NORS485 D1RS485 DØN/CN/CSys OK Relay NCRS485 COM
Pin Nº Colour Function
Connector A (Male)
Connector B (Male) Connector C (Female)
6
5
43
1
87
2
10
9
6
5
43
1
87
2
10
9
A - 17
Opacity and Dust Monitor
User Guide
Model 4400
A3.12 Cable SpecificationCabletypesrecommendedbyLAND.
Electri-cal Con-nections Overview
Nº of Cores
Core Size mm2
Core Size strands/
dia
Core Size awg Screened Supplied
by
1 3 0.5 16/0.2 22 Yes LAND2 8 0.25 7/0.2 24 Yes LAND3 8 0.25 7/0.2 24 Yes LAND4 4 0.5to
1.516/0.2to30/0.2
22 to 16 No Customer
5 3 1.0 32/0.2 18 No Customer
12
53
4
FLUE GAS STREAM
Opacity and Dust Monitor
User GuideA - 18
Model 4400
A4 Auxiliary Power Supply (APS42) Connections
Instrument Connections Customer Connections01 Mains Input Earth02 Mains Input Live03 Mains Input Neutral040506
+24V dc, Cable A, Red 07080910
0V, Cable A, Blue 11Cable A, Screen 12
13 Transceiver Shutter A14 Transceiver Shutter B15 Retro Shutter A16 Retro Shutter B17 Transceiver Blower Pressure Switch (Common)18 Transceiver Blower Pressure Switch (NO)19 Retro Blower Pressure Switch (Common)20 Retro Blower Pressure Switch (NO)
Cable B, Red 21 In Cal Relay NOCable B, Blue 22 Alarm Relay COM
Cable B, White 23 Alarm Relay NOCable B, Yellow 24 4 to 20 mA Output +Cable B, Green 25 4 to 20 mA Output -
Cable B, Screen 26Cable B, Black 27 In Cal Relay COM
Cable B, Brown 28 Alarm Relay NCCable B, Violet 29 In Cal Relay NC
Cable C, Screen 30Cable C, Red 31 System OK Relay COMCable C, Blue 32 System OK Relay NO
Cable C, Green 33 RS485 D1 (Data +)Cable C, Yellow 34 RS485 D0 (Data -)
35 No Connection36 No Connection
Cable C, White 37 System OK Relay NCCable C, Black 38 RS485 COM
GETTING STARTED
B
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B Getting Started
B1 The User InterfaceTheModel4400isoperatedfromtheUserInterfaceintheTransceiver.TheUserInterfacehasfourfunctionkeys,andfourilluminatedindicators.Theliquidcrystaldisplaynormallyindicatestheopacitymeasuredbytheinstrument.Errormessagesandotherparameterscanalsobedisplayed,asexplainedinalatersection.ThedisplayedopacityiscorrectedforPathlengthCorrectionFactor(PLCF).ThePLCFisfactorysetandcannotbechangedbythecustomer(seesectionC1.3).
1 Power on 4 Alarm Status 2 System status 5 LCD 3 Calibration in progress 6 Function keys
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User GuideB - 2
Model 4400
B2 Function KeysThe following function keys are located on the touch panel below the LCD display on the side of the Model 4400 Transceiver: Exit.Returntothepreviousmenulevelorcanceldataentry. Up.Changemenuitemorincreasedatavalue. Down.Changemenuitemordecreasedatavalue. Enter.Selectmenuitemorsavedataentry.
1. Displayed ValueWhen the LCD display is showing only the instrument reading, pressing the
or arrowswillchangethevaluedisplayed.Iftheunitsare%,thevalueis Opacity, if the units are mg/m3,thevalueisDustDensity.Ifnounitsareshown,thevalueisOpticaldensity.
2. Menu Selection
When the LCD display is showing only the instrument reading, press or togotothemenu.
Use the and arrowstoselecttherequiredmenuitemandpress
To cancel a menu selection, press
3. Data EntryTo change a data value, use the arrow to increase the value and the arrowtodecreaseit.When the value is correct, wait for the icon to appear, then press to storeitpermanently.To abandon the change and revert to the previous value, press TheModel4400providesanacceleratorfacilityforenteringlargenumbers.To increase the value, hold down the arrow.Thelongeryouholddownthekey,thequickerthevalueincreases.Initially,valuesincreaseinstepsof1,thenstepsof10,thenstepsof100,andsoon.Whenyoureleasethekey,thehighlightstepsdownthedigits.Youcanpresstheupordownkeyagaintomakeminoradjustmentstothehighlighteddigit.To store a value, wait until the highlight is on the last digit and the symbol is present, and then press the key.Pressing leavestheoriginalvalueunchanged.Itisnotpossibletostoreavaluewhichisoutoflimits.Decreasing the value using the arrowworksinasimilarmanner.
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27 Alarm type (Transceiver alarm)
271 Alarm type (AFU 1)
272 Alarm type (AFU 2)
31 Calibration check interval
32 Show negative
33 Alarm level (Transceiver alarm)
331 Alarm level (AFU 1)
332 Alarm level (AFU 2)
34 O/P type (Transceiver output)
341 O/P type (AFU 1)
342 O/P type (AFU 2)
35 O/P range (Transceiver output)
351 O/P range (AFU 1)
352 O/P range (AFU 2)
36 Constant current (Transceiver)
361 Constant current (AFU 1)
362 Constant current (AFU 2)
37 Dust settings
41 Parameter number
42 Parameter Scroll
Model 4400 Symbols
1 Enter
2 Exit
3 Up
4 Down
6 Unlock
7 Supervisor unlocked
8 Engineer unlocked
9 Lock
10 Locked
11 AFU present (or faulty if flashing)
12 Isokinetic average in progress
15 Calibrate
16 Settings
17 Parameters
18 Diagnostics
19 AFU settings
21 Cal check
22 Recalibrate
23 Cal Audit
24 Gravimetric test
25 Confirmabort
26 Fuelspecificsettings
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Model 4400
45 List faults
46 Clear faults
51 Dust gain 1
52 Dust gain 2
53 Dustoffset
54 Fuel 1 in use
541 Fuel 2 in use
542 Fuel 3 in use
55 Zero check
56 Upscale check
61 Confirmclearpath
62 Confirmblockedpath
63 Testfilteropacity
65 Not averaged
66 Averaged
71 Start
72 Stop
73 Wait
75 No Negative Values
76 Show Negative Values
81 Opacity
82 Optical Density
83 Dust Density
85 Restore Previous Cal
86 Restore Last Cal
87 Restore Factory Cal
88 ConfirmRestoreCal
89 Completed OK
91 C Constant
92 XConstant
93 B Constant
98 Internal Communication Error
99 Major Internal Fault
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B3 Glossary of Terms
Op Opacity O.D. OpticalDensity Dust Dust Density Averaging Time period used to calculate block average Loop O/P Current loop output reading in mA Version Software Version Number Blank A blank line So SignalDetectorOffset Sf Signal Detector Flood Value Sm Signal Detector Measurement Value Ro ReferenceDetectorOffset Rf Reference Detector Flood Value Rm Reference Detector Measurement Value C Calibration Constant (slope) X Calibrationconstant(offset) B Balance correction G Gain correction factor Q Uncorrected transmission factor DustGain ConstantrelatingOpticalDensitytoDustDensity. DustOffset DustDensityzerooffset(usuallyzero) Dust Gain 2 Quadratic term relating optical density to dust density (usually zero) OPDamper Lowpassdigitalfilterappliedtooutput PLCF Pathlength Correction Factor GravimetricO.D AverageOpticalDensitycalculatedduringgravimetrictest
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Model 4400
B4 Using the Instrument for the First TimeToolsrequired:• Flat-bladed electrician’s screwdriver• 17 mm spanner (11/16 in AF wrench)•19mmspanner(3/4inAFwrench):Ifusingthe3inAdaptorflanges.
Note
When entering numbers using the and arrows on the keypad, wait until the symbol appears on the display before pressing the key to confirmthevalue.
B4.1 Complete InstallationEnsure that the installation has been completed and that the purge air blowersarerunning.
B4.2 Align the Retro-Reflector
Quick Release Clip
Captive Screws
Reflectorinstowed position
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OpeningtheRetro-ReflectorCase&ReleasingtheReflector1) OpentheRetro-Reflectorcasebyundoingthetwoquick-releaseclamps.2) ReleasetheRetro-ReflectorMountbyunscrewingthetwocaptive
screwsoneithersideoftheRetro-ReflectorMount.Removethereflectorandstowinthepurgehousing.
3) Closethecaseandfastenthequick-releaseclamps.
Warning
Eye and face protection must be worn when looking into hot gases.
4) Observethealignmenttargetthroughthewindow(3).Abrightgreenspot(4)shouldbevisible.
5) If the green spot is not visible undo thequickreleaseclampontheRetro-Reflectorandlookdownthepurgebarrel.ThebrightgreenlightfromtheTransceivershouldbeclearlyvisible.If not, then the Transceiver is either grossly misaligned or the instrument is malfunctioning.
6) To move the green spot horizontally adjust the M10 nut (1) on the air purge flangeandtomoveitvertically,adjustthe M10 nut (2), also on the air purge flangeasillustratedabove.Adjustthesenuts until the green spot is central in the innercircle.
7) In bright sunshine the green spot on the alignment target may not be visible.Inthiscasereturntothetransmissometer,undothequick–releaseclampsandswingtheinstrumentawayfromthepurge.ItshouldnowbepossibletoadjusttheRetro-Reflectoruntilthebrightcircle of sunlight, visible through the transmissometer purge unit, is centredonthetarget.
8) Ensure that the 4 pairs of spring washers between the air purge flangeandthemountingflangeareundermoderatecompression.Itisimportantthattheinstrumentisfirmlyheldinplacetomaintainopticalalignment.
9) OpentheRetro-Reflectorcase,re-fixtheRetro-Reflectorinposition,andtightenthecaptivesocketheadscrews.ClosetheRetro-Reflectorcaseandfastenthetwoquick-releaseclamps.
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Model 4400
B4.3 Align the Transceiver
Transceiver Alignment Target1 Observethealignmenttargetthroughthewindow(3).Abrightgreen
spot(4)shouldbevisible.2 To move the green spot horizontally adjust M10 nut (1) on the air purge
flangeandtomoveitvertically,adjusttheM10nuts(2),alsoontheairpurgeflangeasillustratedabove.Adjustthesenutsuntilthegreenspotisinsidetheinnercircle.
3 In bright sunshine the green spot on the alignment target may not bevisible.InthiscasereturntotheRetro-Reflector,undothequick–releaseclampsandswingopentherearcover.Itshouldnowbepossibleto adjust the transmissometer until the bright circle of sunlight, visible throughtheRetro-Reflectorpurgeunitiscentredonthetarget.ClosetheRetro-Reflectoragain.Ifthegreenspotisvisible,adjustthenutsuntilitiscentralintheinnercircle.
4 Ensurethatthespringwashersbetweentheairpurgeflangeand themountingflangeareundermoderatecompression.Ifthecompression becomes excessive, it is likely that the third nut has beenovertightenedorthemountingflangemaynothavebeenfittedaccurately.
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Note
If any of the settings are changed from their default values, the new values should be noted on the Calibration Report and Settings List suppliedwiththeinstrument.
B4.4 Setup 4-20 mA Current Loop OutputThe Model 4400 normally provides the power supply for the 4-20 mA current loopoutput.Itisintendedtobeconnectedtoapassiveinputdevice.Toconnect the 4-20 mA current loop output to an active device, option links insidetheTransceivermustbechanged.Switchoffthepower.Removetherear cover from the Transceiver (see section E3) and locate Link 1 and Link 2 ontheMainprintedcircuitboard.The Model 4400 is shipped set for Active output with the Links in the following positions: Link 1: A Link 2: BFor Passive output, set the Links in the following positions: Link 1: B Link 2: A
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User GuideB - 10
Model 4400
Toconfigurethe4-20mAcurrentloopoutput:
1) From Settings , press
2) Use the and arrows to select Output Type and press
3) Use the and arrows to select Opacity , Optical Density
, Dust Density , Constant Current , Calibration Drift or Pathlength Correction Factor and press
4) Press toreturntoOutputType.
5) Use the and arrows to select Output Range and press
6) Use the and arrows to change the output value corresponding to 20mA and press
7) Press toreturntoOutputRange.
8) Use the and arrows to select Show Negative Values and press
9) Use the and arrows to select Show Negative Values or No
Negative Values and press
10) Press to return to Show Negative Values
Ifrequired,thecurrentloopoutputcanbesettodeliveraconstantcurrentfortestpurposes.
11) Use the and arrows to select Output Current and press
12) Use the and arrows to change the output current and press
13) When the test is complete, press toswitchbacktonormaloperation.
14) Press to return to Settings
B4.5 Setup Alarm
1) From Settings , press
2) Use the and arrows to select Alarm Type and press
3) Use the and arrows to select Opacity , Optical Density or
Dust Density and press
4) Use the and arrows to select Alarm and press 5) Use the and arrows to change the Alarm Level and press
6) Press to return to Settings .
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B4.6 Modbus InterfaceModbus communications, based on the RS485 duplex hardware standard, providedirectaccesstotheModel4400systemdata.DetailsoftheModbusprotocolareavailablefromtheModbuswebsitewww.modbus.org.TheModel4400implementsFunctions:1(ReadCoil),3(ReadHoldingRegister),5(Force Single Coil), 6 (Pre-set Single Register) and 10 (Pre-set Multiple Registers)Each Modbus must have one termination resistor at each end and one bias networksomewhereonthebus.TheModel4400canprovideaterminationresistorandabiasnetwork.Assupplied,theterminationresistorisswitchedon,andthebiasnetworkisswitchedoff.Tochangethese,switchoffthepower, remove the rear cover from the Transceiver (see section E3), and locateswitchS1ontheMainprintedcircuitboard.ThefoursectionsofS1have the following functions: 1 and 2 Bias network Supplied OFF 3 Not used 4 Termination resistor Supplied ON
The Model 4400 is shipped with the following default communications settings:
Baud rate: 57600 Parity: Even Data bits: 8 Stop bits: 1 Slave Address: 7
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Model 4400
The Baud rate, Parity and Slave Address can be changed as follows:1) Press
2) Use the and arrows to select Parameters and press
3) Use the and arrows to select Parameter Number and press 4) Use the and arrows to change the Parameter number to 1 and
press 5) Use the and arrows to change the Slave Address to the desired
number in the range 1 to 247 and press 6) Use the and arrows to change the Parameter number to 2 and
press 7) Use the and arrows to change the Baud Rate to 9600, 19200,
38400, or 57600 and press 8) Use the and arrows to change the Parameter number to 3 and
press 9) Use the and arrows to change the Parity to 0 (None), 1 (Even), or
2 (Odd) and press 10) When the communication settings are correct press twice to return to
themainscreen.
Any writeable Modbus register can be changed using the Transceiver Control panel as follows:1) Press
2) Use the and arrows to select Parameters and press
3) Use the and arrows to select Parameter Number and press 4) Use the and arrowstoselecttherequiredParameter(register)
number, then press 5) Use the and arrows to change the parameter value to the desired
value and press 6) Press twicetoreturntothemainscreen.
B4.7 Modbus RegistersAbrieflistofthemostusefulRegistersisgivenbelow.AfulllistisincludedontheCD-ROM.
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Note
ThedefinitionofRegisterNumbersgivenintheModbusstandardcancauseconfusion.Forhistoricalreasons,Registersaregivendecimalnumbersbeginningat1,butRegister1islocatedatAddressOffset0.Registernumbersarealwaysonegreaterthantheirassociatedbusaddresses.TheTablebelowusesRegisterNumbers.
ScalingIn the following table, the value in the Modbus register must be divided by thescalingfactortoobtaintheactualvalue.
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Model 4400
Read-Only Registers Modbus Register
Data Value Description Range Scaling
127 Opacity Calculated opacity -25% - 100% x100
128 Optical density Calculated optical density -1 - 3 x1000
129 Dust density Calculated dust density 0 - 9999 x1
130 Dust density fractional
Fractional part of the dust density (Reg 503)
0 - 99 x100
131 Average optical density
Average optical density during gravi-metric test
-1 - 3 x1000
132 Stored Average Optical Density
Stored average optical density -1 - 3 x1000
133 Heldopacity Calculated opacity not updated during a cal audit or a cal check
-25% - 100% x100
134 Heldopticaldensity
Calculated optical density not updated during a cal audit or a cal check
-1 - 3 x1000
135 Helddustdensity Calculated dust density not updated during a cal audit or a cal check
0 - 9999 x1
136 Helddustdensityfractional
Fractional part of the held dust density (Reg 506)
0 - 99 x100
73 Alarm status Transceiver alarm 0 = Inactive1 = Active
NA
51 Number of faults Indicates the number of faults currently present (regardless of mask states)
0 - 32 NA
52 Error Flags Errorflags Bit 0 = Zero motor jammedBit 1 = Upscale motor jammedBit 2 = Source LED failBit 3 = Flood Led failBit 4 = ADC over-rangeBit 5 = ADC faultBit 6 = Tx shutter faultBit 7 = Retro shutter faultBit 8 = Tx blower faultBit 9 = Retro blower faultBit 10 = AFU faultBit 12 = Negative opacityBit 13 = Checksum errorBit 14 = Lens contamination limitBit 15 = Failure during cali-bration
NA
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Model 4400
Read-Write RegistersModbus Register
Data Value Description Range Scaling
201 Average during audit 0=Off1 = On
NA
Note
A Read operation on an unassigned Register will return a zero, rather thananexception.
SomestatusconditionscanalsobeaccessedasModbuscoils.RefertotheModel 4400 Modbus guide for more details
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Model 4400
B5 Periodic Modes of Operation
B5.1 Online Manual Calibration CheckThe Model 4400 has a convenient calibration audit facility which allows you to performamanualzerocheckwhiletheprocessisoperating.Italsoallowsalinearitychecktobedoneusingtraceablecalibratedneutraldensityfilters.
Calibration Audit1) Press
2) Unlock isdisplayed.Press3) Use and until the supervisor code is displayed and press
4) Select the Calibration menu
5) Select Cal Audit
6) Fast Response isdisplayed.Press7) Insertthezeroreflectorintothefrontfilterslot,furtherfromthemain
lens.TheModel4400willdisplaythezerovalue. A value greater than +/- 2% indicates a calibration drift and the Model
4400shouldberecalibrated.RefertoB5.38) To check the linearity of the Model 4400, insert a calibrated neutral
densityfilterintotherearfilterslot9) Whenthecalibrationcheckiscomplete,removethezeroreflectorand
anyauditfilters
10) Select Stop and press toendthecalibrationcheck.11) Press twice to return to the
mainscreen.12) Insert a calibrated neutral density
filterintoslot1,takingcarenottotouchtheglass.Readandrecordthedisplayedopacityvalue.
13) Note that this value is path-length corrected.IfthePLCFissetto1.0,the displayed value should match thefilteropacity.IfthePLCFisnot1.0,usethefollowingformulatocalculate the expected instrument reading:
14) TheoperatingwavelengthoftheModel4400is525nm.Allauditfilters
willbecalibratedatthiswavelength.15) Removethefilter,insertthenextfilterandrecordthereading.16) Afterthefinalreading,removethezeroreflectorfromtheslot.
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Model 4400
Exit from Audit ModeUse the and arrows to select Stop and press Theinstrumentresumesnormaloperation.Press twicetoreturntothemainscreen.
B5.2 Recalibration (Also known as Zero Alignment or Clear Stack Calibration)A Recalibration must only be performed when there is no smoke or dust in thebeamoftheopacitymonitor.TocomplywithUSEPAProcedure3,theinstrumentmustberemovedandattachedtoteststandsforcalibration.The Model 4400 provides a convenient facility for testing on a workbench or otherflatsurface.TheTransceivermaybelaidonitsleftsideandtheRetro-reflectoronitsrightside;thescrewintheleftsideofthetransceivercasecanbeadjustedtoachievethecorrectalignment.ItisessentialthatthedistancebetweentheTransceiverandtheRetro-reflectorisadjusteduntilitexactlymatchesthedistanceinnormaloperation±6mm(1/4”).Ensure that the pathlength is correct and that the surfaces of the main lens andretro-reflectorelementsarecleananddustfree.AligntheinstrumentasdescribedinB1.4paragraph3.1) Press
2) Unlock is displayed, press 3) Use the and arrows until the Supervisor code (Default: 10) is
displayed and press
4) Use the and arrows to select Calibrate and press
5) Use the and arrows to select Recalibrate and press
6) Start isdisplayed.Whenready,press
7) Confirmclearpath isdisplayed.Checkthattheopticalpathisclearandthattheopacityreadingisstable.Press
The hourglass is displayed while the instrument waits an additional 10secondsforthereadingstosettle.
8) Confirmblockedpath isdisplayed.Thesimplestwaytoachieveablocked path is to release the clips on the side of the Transceiver and swingitopenonitshingesuntilthebeamispointingintofreespace.Alternatively, to calibrate the instrument at an opacity other than 100%, insertafilterintotheslotinthecalibrationunit,closetheTransceiveronitshingesandapplytheclips.
9) When the reading is stable, press .Thehourglass is displayed while the instrument waits an additional 10 seconds for the readings to settle.
10) Filter Opacity isdisplayedandthevalueispre-setto100%.IftheTransceiver was pointed into free space, or if the beam was completely blocked, press .Ifacalibratedfilterwasused,settheopacityofthefilterwiththe and arrows and press
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Model 4400
11) Insertthezeroreflectorandpress
12) The hourglass isdisplayedwhiletheinstrumentcollectsdata.13) Removethezeroreflectorandpress to complete the calibration14) If you have an optional External Zero Device (EZD), it must be
recalibratedafterperformingaClearStackCalibration.RefertoSectionB5.8.
B5.3 Gravimetric Calibration (Isokinetic Calibration)TheModel4400measurestheopacityofdustandsmokeemissions.Asexplained in the Reference section of the manual, this may be converted toDustDensityusingcalibrationconstants.Todeterminethesecalibrationconstants it is necessary to collect and weigh samples of the particulate matterfromthefluegases.ThisproceduremustbecarriedoutinaccordancewithrelevantUSEPAMethodsorCENorISOStandards.ItisgenerallyknownasGravimetricorIsokineticSampling.Model 4400 provides a facility to simplify collection of readings during GravimetricCalibration.
To record the Average Optical Density during a Gravimetric Test:1) Press
2) Unlock is displayed, press 3) Use the and arrows until the Supervisor code (Default: 10) is
displayed and press
4) Use the and arrows to select Calibrate and press
5) Use the and arrows to select Gravimetric Test and press
6) Start isdisplayed.WhentheGravimetricTestisstarted,press The display will show the Average Optical Density since the start of the
test.
7) Stop isdisplayed.WhentheGravimetricTestiscomplete,press TheAverageOpticalDensityduringthelasttestisshown.Recordthe
value.
Note
Do not press while the Gravimetic Test is running as this has the sameeffectaspressing .ThetestisterminatedandthecurrentAverageOpticalDensityisstored.
8) Start isdisplayed.Tostartanewtest(andlosethesavedvalue)press
9) To leave the Gravimetric Test menu, press 10) Press twicetoreturntothemaindisplay.
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To calculate calibration constants from the results of a series of Gravimetric Tests:The procedures for formally calculating the calibration constants are given in USEPAPerformanceSpecification11,orCENStandardsEN13284-2andEN14181.AsimplifiedprocedureusingMicrosoftOfficeExcelisgivenbelow:1) For each measurement point, determine the Dust Density at the
reporting conditions from the Gravimetric Test procedure, and the averageOpticalDensityindicatedbytheModel4400duringthetest.
2) Plot a Scatter Chart of Dust Density (Y axis) against Optical Density (XAxis).AddaLinearTrendlinethroughtheorigin(0,0)andshowtheequationoftheTrendlineonthechart.TheslopeoftheTrendlineistheDustGaincalibrationconstant.DustOffsetandDustGain2arezero.
3) IftheTrendlineisnotagoodfittothedata,tryremovingtheconstraintfortheTrendlinetogothroughtheorigin.TheTrendlineoffsetistheDustOffsetcalibrationconstant.DustGain2iszero.
4) If the data points form a marked curve rather than a straight line, changetheTrendlinetoaPolynomialoforder2.Thecoefficientofthex2 termistheDustGain2calibrationconstant.
To enter the calibration constants into the analyser:Model4400canrecorduptothreesetsofcalibrationconstants.Eachsetisassociatedwitha“FuelNumber”becausetheyareintendedtofacilitatechangesoffuel.Theycouldequallybeusedfordifferentloadoroperatingconditionsbyassigning“FuelNumbers”tothese,asrequired.The“CurrentFuel”describedbelowreferstothesetofcalibrationconstantswhichtheanalyser is currently using to calculate Dust Density in mg/m3.1) ToentertheDustGainandOffsetvaluesintotheModel4400,press
2) Unlock is displayed, press 3) Use the and arrows until the Supervisor code (Default: 10) is
displayed and press
4) Use the and arrows to select Settings and press
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Model 4400
B5.4 Restoring Previous Calibration ValuesIf the Model 4400 is mis-calibrated, it is possible to recover the situation by replacingtheerroneouscalibrationconstants.ThePreviousconstants,andtheconstantsdeterminedduringFactorytestingarestoredintheinstrument.
To replace the Current Calibration constants with the Previous constants:
1) Press
2) Unlock is displayed, press 3) Use the and arrows until the Supervisor code (Default: 10) is
displayed and press
4) Use the and arrows to select Calibration and press
5) Use the and arrows to select Previous Cal and press
6) Use the and arrows to select Restore Last Cal and press
7) Confirm isdisplayed.Press8) The Previous Calibration constants are copied into the Current
Calibrationconstants.
9) The Tick in the top left corner of the display indicates that the operationwassuccessful.
10) Press threetimestoreturntothemaindisplay.
To replace the Current Calibration constants with the Factory constants:1) Press
2) Unlock is displayed, press 3) Use the and arrows until the Supervisor code (Default: 10) is
displayed and press
4) Use the and arrows to select Calibration and press
5) Use the and arrows to select Previous Cal and press
6) Use the and arrows to select Restore Factory Cal and press
7) Confirm isdisplayed.Press The Factory Calibration constants are copied into the Current Calibration
constants.
8) The Tick in the top left corner of the display indicates that the operationwassuccessful.
9) Press threetimestoreturntothemaindisplay.
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B5.5 Setting Calibration Constants ManuallyIn the event of a major malfunction resulting in loss of the calibration data, the Model 4400 provides a facility for entering the calibration constants manually.TheoriginalcalibrationdatadeterminedduringfactorytestingarerecordedontheCalibrationReport.Thismayalsoshowcalibrationdatadeterminedduringlaterclear-stackcalibrations.Toenterthecalibrationconstants,C,XandB:1) Press
2) Unlock is displayed, press 3) Use the and arrows until the Engineer code is displayed and press
4) Use the and arrows to select Calibration and press
5) Use the and arrows to select the C Constant and press 6) Use the and arrowstochangethedisplayedvalueasrequiredand
press
7) Use the and arrowstoselecttheXConstant and press 8) Use the and arrowstochangethedisplayedvalueasrequiredand
press
9) Use the and arrows to select the B Constant and press 10) Use the and arrowstochangethedisplayedvalueasrequiredand
press 11) Press threetimestoreturntothemaindisplay.
THEORY OF OPERATION AND APPLICATION
C
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C Theory of Operation and Application
C1 General Outline
When a beam of light crosses a medium containing smoke or dust particles, someofthelightistransmittedandsomeislostduetoscattering.Thefraction which is transmitted is called the transmittance and the fraction whichislostistheopacity.In the early days of emissions measurement, the opacity of the smoke leaving a stack was measured by the Ringelmann method in which a trained observermakesavisualestimateofitsappearance.Modern methods for opacity measurement are far more sophisticated than theRingelmannmethod,butmanyofthespecificationsrelatebacktothewaythehumaneyeseessmokeemissions.Thewavelengthresponseofanopacitymonitormustmimicthatofthehumaneye.Aninstrumentmusthaveanearlyphotopicresponse.TheLandModel4400usesahigh-intensitygreenLEDlightsourcetoachievethis.
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Model 4400
C2 Beer-Lambert’s LawThe mathematical relationship between the light transmitted by a medium andthequantityofpollutantpresentisknownastheBeer-LambertLawandmaybewritten; τ = I = e -acL
Iwhere: τ = Transmittance Io = Intensity of light into the medium (see 1 below) I = Intensity of light out of the medium (see 3 below) a = AttenuationCoefficient c = Concentration of Pollutant L = Distance light beam travels through the medium (see 2 below)
1
2
3
Since opacity (Op) = 1 - τ,theaboveequationbecomes: (1 - Op) = e -acL or Op = 1 - e -acL
Notethatthequantitycistheamountofdustintheopticalpath.OpticalDensity(orextinction)isdefinedas; OD = -log10τ = -acL/2.303 c = k x OD where k = -2.303 aLBy comparing a series of optical density measurements with gravimetric dust mea-surementstakenatthesametime,itispossibletodeterminethevalueofk.
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C3 Physical Principles
C3.1 General DescriptionThe Land Instruments International Model 4400 Continuous Opacity Monitoring System (COMS) measures opacity by shining a light beam throughfluegases.Aninternalmicroprocessorcalculatesopacity,dustdensityandotherparameters.Theinstrumentcomprisesthefollowingparts: The Transceiver which contains all of the optical and electro–optic components;theRetro-Reflectorcontainingaglassreflectorandtheairpurgesystem.The air purge system can take several forms depending upon individual siterequirements.Singleanddualelectricblowersareavailable,asarecompressed-airdrivendevices.Continuouspurgeairsupplyisessentialtopreventdustandcorrosivegasesfromaffectingtheopticalsystem.Automaticfail–safeshutterscanalsobefittedfortemporaryprotectionintheeventofapurgeairfailure.The entire system is designed for continuous operation in all weather conditions,withminimalmaintenance.
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C2.2 Principle of OperationThe Land Model 4400 has been developed from the highly successful Land Model 4500 MkIII, which already has a well-deserved reputation for reliabilityandaccuracy.ThemainlightsourceusesthreegreenLEDsinaspecialconfiguration(patentpending)toensurehomogeneityovertheentiretransmittedlightbeam.Thelightsourceismodulatedatafrequencyof1kHz,toreduceelectricalnoiseandeliminateerrorsduetoambientlight.Asecondlightsource,the(patented)“FloodLED”isusedtoreducetheeffectoftemperaturedriftinthedetectorstoanalmostimmeasurablelowlevel.Electronic modulation eliminates the need for a mechanical chopper and so theonlymovingpartsarethemotorsusedinthecalibrationsystem.Thesemotorshaveaverylowdutycycleandareveryreliable.
Transmissometer Key
1. LEDlightsource 7. ReferenceDetector 2. FloodLED 8. ConcaveMirror 3. 50/50BeamSplitter 9. Diffuser 4. CollimatingLens 5. CollimatedBeam 6. MeasurementDetectorTheTransceiverisillustratedabove.LightfromsourceLED1(1)passesthroughthediffuser(11)andontothe50/50beamsplitter(3).Thetransmittedportionpassesontothelens(4)whichprojectsawell-defined,collimated beam (5) across the measuring path to the distant Retro-Reflector.Lightreturnedfromtheretro-reflectorisfocusedbythelens(4)ontomeasurementdetector(6).Theportionoflightoriginallyreflectedbythe beamsplitter (3) falls on the concave mirror (8) which focuses it on to referencedetector(7).Theopacityvaluecanbecalculatedfromtheratioofthesignalsfromthetwodetectors.
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This is true only as long as long as the responsivity of the detectors (6 and 7)andthegainoftheirassociatedelectronicsremainsconstant.Inpractice,temperature variations and ageing of the components means that this cannot beguaranteed.TheModel4400usesanovelmethodtocompensateforsuchchangesbyusingFloodLED(2)toilluminatebothdetectors(6and7).Because it uses no focusing optics, there is no possibility of misalignment and so any relative change in sensitivity between the detectors (6) and (7)willleadtoachangeintheratioofsignalsfromtheFloodLED(2).Byalternating light sources (1) and (2), the normalisation procedure is then continuous.Themicroprocessorperformsthecalculationsrequiredtoperformthenormalisation and to convert the opacity measurement into optical density or dustdensityasrequired.
SYSTEM SPECIFICATION
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D System Specification
D1 4400 Dust and Opacity Monitor
MeasuringTechnique: Doublepasstransmissometry
Operating Wavelength: 520 ±20 nm
LightSource: PulseHighIntensityLED
Range: Opacity: 0 to 10 % to 0 to 100 %
OpticalDensity:0to0.1to0to3.0
Dust Density: 0 to 20 to 0 to 1000 mg/m3 (at 5 m pathlength)
User Selectable
CalibrationError: 1.5%Opacity
Drift: <0.3%Opacitypermonth
ThermalStability: 0.6%Opacity/22°Cchange
Angle of Projection: 2 o
Angle of View: 2 o
ResponseTime: <10secondsto95%offinalvalue
Averaging: Selectable from 10 seconds to 24 hours (in 1 second steps)
Pathlength: 0.5to10m/20into32ft
Calibration: Manual online calibration check
Control Panel Display: 128x64pixelreflectivebacklitLCD
Keypad: 4 keys for data input
Indicators: Power, System OK, Calibration, Alarm
Environmental Operating temperature: -40 to 55 oC / -40 to 131 oF
Maximum Flue Gas temp: 600 oC / 1112 oF
Maximum Flange temp: 200 oC / 392 oF
Electrical Safety: IEC / EN 61010-2
EMC: EN50081&EN50082
Sealing: IP65/NEMA4X
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Outputs ModbusInterface: RS485.Opacity,OpticalDensity,Dust Density, and Status Information available
AnalogOutputs: Isolated4-20mAcurrentoutput.
ConfigurableasOpacity,OpticalDensity, Dust Density
Relay Outputs: System OK, Calibration, Alarm
Relay Rating: 1 A @ 24 V dc
ElectricalPower Supply: 24 V dc nominal (18 to 30 V dc)
CurrentConsumption: 0.3Anominal(3Astartup)
Mechanical DataDimensions(HxWxD)
Transceiver: 191x201x413mm/7.5x7.9x16.3in
Retro-Reflector: 191x201x237mm/7.5x7.9x9.3in
WeightTransceiver: 6kg/13.2lb
Retro-Reflector: 3kg/6.6lb
EnclosureTransceiver/Retro-Reflector: CastAluminium,epoxycoated
Protective PurgePurgeairrequired: 30m3 / hr / 18 cfm each side
AccessoriesAvailable: Fail-safe Shutters
Blowers
Adapter Flanges
Mains Power Supply (APS42)
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D2 Auxiliary Power Supply (APS42)Operating Temperature: -40 to 55 °C (-5 to 130 °F)
Environmental Rating: IP66, NEMA4
OperatingHumidity: 20to95%RH,non-condensing
Input Voltage Range: 85 to 264 V AC
InputCurrent: 1.1A@115VAC/0.59A@230VAC
InputFrequency: 50to60Hz
Output Voltage: 24V DC
Weight: 8.6kg/19lb
MAINTENANCE
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E Maintenance
E1 Identifying FaultsThe Land Model 4400 Dust and Opacity Monitor has been designed to assist theusertofindandcorrectanumberofpossibleproblems.IftheinstrumentdetectsaproblemitwillswitchofftheGreenSystemOKLEDandde-energisetheSystemOKrelay.Further diagnostic information may be obtained as follows:1) Press
2) Use the and arrows to select Diagnostics and press The number of faults present is shown in the top left corner of the
display.3) If the number of faults is not zero, use the and arrows to select
List Faults and press ThefirstFaultNumberisdisplayed.Itsmeaningandtherecommended
actionarelistedintheTableopposite.4) Use the and arrowstoseeanyotherFaultNumbers.Ifthereare
nootherfaults,thenumberwillnotchange.5) Press
6) To clear the faults, use the and arrows to select Clear Faults and press .Thenumberoffaultswillbeupdated.Iftherearestillfaultspresent,thiswillnotbezero.
Note
The list of displayed faults is only updated on entry to the diagnostics menu,andinresponsetoaClearFaultsinstruction.ChangesinfaultstatuswhiletheDiagnosticsmenuisinusemaynotbevisible.
7) Press toreturntothemainscreen.
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Fault Number List
Fault Number
Description Recommended Action
3 Source LED failed ChecktheSourceLEDconnections.ReplacetheSourceLEDAssembly.
4 Flood LED failed ChecktheFloodLEDconnections.ReplacetheFloodLEDAssembly.
5 ADC Over-range ThesignalarrivingattheAnalogue-to-DigitalConverteristoolarge.Checkthatthecorrectreflectorelementandapertureplatearefittedintheretro-reflector.ReplacetheDetectorPCB.Warning–TheDetectorPCBmustbeopticallyaligned.
6 ADC Fault TheAnalogue-to-DigitalConverterisnotworking.ReplacetheDetectorPCB.Warning–TheDetectorPCBmustbeopticallyaligned.
13 Negative Opacity Checkthattheinstallationpathlengthiscorrect.PerformaClearStackCalibration.
14 Checksum Error Themicroprocessor’sprogrammemoryisdefective.Re-programtheMainPCB.ChangetheMainPCB.Warning–AlloftheinstrumentsettingsandcalibrationconstantsarestoredontheMainPCB.Re-enterthisdataafterchangingthePCB.
16 Failure during Calibration Somethinghaspreventedcompletionofacalibration.Useractionscancausethisfault.PerformaCalibrationCheck.Iftheproblempersists,checktheZeroReflectorandUpscaleFilterdrivemechanisms.Warning–Do not move either mechanism by hand or the precision gearbox may be irreparablydamaged.
Note
When contacting Land Instruments Service Department please have the InstrumentTypeandSerialNumberavailable.Thiswillensureamoreaccurateandefficientresponse.
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E2 Routine MaintenanceThe Land Instruments International Model 4400 has been designed for a minimalamountofroutinemaintenance.Toensureamaximummonitorlifetimehowever,thefollowingmaintenanceschedulehasbeendeveloped.Remember that the air purge system should always be left on, even if the boilerisoff,topreventanycontaminationoftheoptics.Inexceptionallydirtyfacilities,thetimeperiodsbelowshouldbeshortened.Frequent“LensContaminationlimit”alarmsorblowerfaultsmayindicateaneedtoshortenthemaintenanceperiod.
Item Part Maintenance ProcedureAirHoses 306.046 90 Days Examinehosesforholesorleaks.Test
allhoseclampsfortightness.Pre-filter(Wherefitted)
317.560 90 Days Dustlevelshouldbebelowtheline.Remove, empty, wipe out, and re-place.
Filter Element
Safety Filter(wherefitted)
317.561
317.604
90 Days
Annually
Removethefilterfromthefilterhous-ing.Removethecap.Emptythecapandwipeout.Weareyeprotection,tapgentlytoremovedust.Cleancarefullywithablowgun.Examineforholesorrips.Re-fit.
Replacewithnewfilter.Blower 90 Days Checkforbearingnoise.(Bearingfail-
ure,andsubsequentblowerfailure,canbedetectedearly.)Checkblowerairflowtobesurethattheblowerisperformingnormally.(Dirtyairfiltersmayreduceairflowandcauseunduestressontheblowers.)
Optics N/A 90 Days Check and clean the optics as de-scribedbelow.
Air Purge Adapter N/A 90 Days Unclip and hinge open the Transceiver andRetro-Reflectorandcheckthatthere is no ash buildup inside the purge adapters that could block the lightpath.
Duringtheregularlyscheduledmaintenanceperiods,anyoptionalequipment(e.g.shutters,pressureswitches,weathercovers)shouldbecheckedforcorrectoperation.Ifanypotentialproblemsarenoted,theequipmentshouldberepairedorreplacedifnecessary.
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Cleaning the Optical SurfacesAfter prolonged use, it is likely that some contamination will occur on theopticalsurfacesoftheModel4400.Thetimetakenforsignificantcontamination to occur depends very much on the nature of the installation, butinatypicalsituationitshouldbesufficienttocleantheopticsevery90days.
CAUTION
Alwaysusealintfreelensclothtocleantheopticalsurfaces.Ensuretheclothiskeptclean.AdirtylensclothcanscratchtheopticalsurfaceandcausepermanentdamagetotheModel4400.Replacement lens cloths can be purchased from Land Instruments International.Ordinary tissues and dusters are not suitable, and can scratch the delicate optical surfaces.
TocleantheRetro-Reflector,openthehousingbyundoingthetwoquick-releaseclamps.CarefullywipetheglasssurfaceoftheRetro-Reflectorwiththelenscloth.Closethehousingandfastenthetwoquick-releaseclamps.To clean the mains lens, open the Transmissometer housing by undoing thetwoquick-releaseclamps.Wipethelensusingthelenscloth.Closethehousingandfastenthequick-releaseclamps.
CAUTION
Donotattempttomovethezeroreflectorbyhand.Theprecisiongearboxwillbedamagedirreparably.
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E3 Removing the Transceiver CoverRefer to this section when you need to remove the transceiver cover to accessinternalswitchesandcomponents.1) Unfasten the clip which secures the rear section of the transceiver and
openuptheunitviathehingesontheoppositesidetotheclip.2) Theinternalfaceofthetransceiverisrevealed(seebelow).Usea3mm
Allenkeytoremovethe8screwsthatsecuretheinstrumentcover.
3) Slowly pull back the red cover until the keyboard connector can be seen.Disconnectthekeyboardribbon,andthenremovethecover.
E3.1 Replacing the Transceiver Cover1) Carefully replace the cover, ensuring that it doesn’t jam on any
components.Whenthecoveriscloseenough,refitthekeyboardconnectorribbon,ensuringitisnotoffsetbyonepin.
2) Ensure the white cord seal is correctly seated before pushing the cover home.Securethecoverwiththeeightscrews.
3) RefastenthecliptoholdtherearoftheTransceiverinplace.
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E4 Replacement Parts and Consumables
Consumables320.804 Lenscloth701.972 Flangesealingring
Spare Parts804348 Purge Assembly 804351 Retro-reflector(withoutPurgeAssemblyorelements)801523 Reflectorelementset0.50mto2.02m801524 Reflectorelementset2.02mto4.30m801525 Reflectorelementset4.30mto10.6m
804320 Main PCB 804319 Detector PCB 804537 Display PCB Assembly 804542 Connector Plate Assembly 804321 Flood LED PCB
804284 Source Assembly 804285 Main Lens Assembly 804283 Eyepiece Assembly 804406 Transceiver case complete 804390 Case clip and hook (304 SS)
804394 Case hinge set – 1 Pair318.238 Hoseclip306.046 Hose39mm–perm
810217 4400ZeroReflector
SparesforStandardMountingFlange703.020
804557 Spherical washer – Set of 3804558 Disc spring – Set of 24804559 M10 Nylock nut – Set of 3804561 M10 Full nut – Set of 3703.021 M10stud809699 Rebuild Kit for Standard Standpipe
APS42 Spare Parts810229 Power Supply Module for APS42
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Identifying Spare Parts
Lens Cloth(PartNumber320.804)
Flange Sealing Ring(PartNumber701.972)
Flange Stud (Set of 3)(Part Number 809645)
809699 Rebuild kit for standpipe comprises one each of 804557, 804558, 804559 and 809645
Spring Washer (Set of 24)(PartNumber804.558)
M10 Locking Nut (Set of 3)(PartNumber804.559)
Spherical Washer (Set of 3)(PartNumber804.557)
CHANGING THE INSTALLATION PATHLENGTH
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F Changing the Installation Pathlength on a Model 4400
F1 Set the correct focusTheTransceiverfocusandretroreflectormustbesetaccordingtotheinstrument’sspecifiedflange-to-flangepathlength.Refertothefocustableonthenextpageforthecorrectfocusspacersetting.1) Removethemainlensassemblybyundoingthethreefixingscrews.2) Removethescrews.Removethelensretainingplatebyturningit
clockwise.3) Carefullyremovethespacers,O-ring,lensandmorespacers.4) Lookuptheflange-to-flangepathlengthinSectionF3overleaf.Findthe
row where the pathlength lies between the values in the minimum and maximumcolumns.
5) MakeanoteoftheLensSpacersandtheReflectorPartNumber.6) The complete set of spacers contains two of each size: 8, 4, 2 and
1mm.Selectspacerswhichadduptothevalueinthetablee.g.18=8+8+2.Putthesespacersintothelensholder.Insertthelens(flatsidedown),thentheO-ringandfinallytheremainingspacers.
7) Replace the retaining plate and lock by pressing down an turning anti-clockwise.Checkthatallthreescrewholesareopen.Ifnot,removeandrepositiontheplate.
8) Replace the lens holder in the Transceiver and tighten the three screws.
F2 Align and Calibrate the Model 4400Thefollowingmustbedoneinalaboratoryoracleanworkshop.Atestkit comprising tabletop stands and power supply available from Land instrumentsandmaketheproceduremoreconvenient.1) Optically align the Model 44002) PerformaclearstackcalibrationusingtheRecalibratefunction.Verify
that the instrument reads 0% opacity on a clear path and 100% opacity whenthebeamisblocked.
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F3 Focus Table
Installation Pathlength (mm)
Installation Pathlength (in)
Focus spacer (mm)
Retro Part
NumberMin Max Min Max514 537 20.2 21.1 30 804342538 562 21.2 22.1 29 804342563 588 22.2 23.1 28 804342589 617 23.2 24.3 27 804342618 648 24.3 25.5 26 804342649 681 25.6 26.8 25 804342682 717 26.9 28.2 24 804342718 757 28.3 29.8 23 804342758 800 29.8 31.5 22 804343801 847 31.5 33.3 21 804343848 900 33.4 35.4 20 804343901 958 35.5 37.7 19 804343959 1023 37.8 40.3 18 8043431024 1095 40.3 43.1 17 8043431096 1177 43.1 46.3 16 8043441178 1269 46.4 50.0 15 8043441270 1375 50.0 54.1 14 8043441376 1498 54.2 59.0 13 8043441499 1642 59.0 64.6 12 8043441643 1812 64.7 71.3 11 8043441813 2020 71.4 79.5 10 8043442021 2272 79.6 89.4 9 8043452273 2585 89.5 101.8 8 8043452586 2991 101.8 117.8 7 8043452992 3532 117.8 139.1 6 804345
3533 4298 139.1 169.2 5 8043454299 5438 169.3 214.1 4 8043465439 7305 214.1 287.6 3 8043467306 10626 287.6 418.3 2 804346
CONFIGURATION RECORD SHEET
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G Configuration Record SheetPleasecompletetheConfigurationRecordSheet.
General Information
Instrument Serial NumberDate of Purchase
Technical Information
Pathlength
Service History
Date Action
Repair History
Date Action Part Replaced PartNo.
For a full list of international offices, please visit our website www.ametek-land.com Copyright © 2019 LAND Instruments International. Continuous product development may make it necessary to change these details without notice. Model 4400 User Guide, Issue 1, 04 June 2019
4400HIGH PRECISION OPACITY AND DUST EMISSIONS COMPLIANCE MONITOR
Land Instruments InternationalDronfield, S18 1DJ, England Tel: +44 (0) 1246 417691Email: land.enquiry@ametek.com www.ametek-land.com
AMETEK Land - Americas 150 Freeport Road, Pittsburgh, PA 15238, U.S.A. Tel: +1 (412) 826 4444Email: irsales@ametek.com www.ametek-land.com
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