Model 4400 User Guide - Publication Nº 813263 - AMETEK Land

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: [email protected]

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: [email protected]

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


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


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.


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


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


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


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


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


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


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


User Guide

Model 4400

4400

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User GuideA - 10

Model 4400

A3.6 Installation with a Fail-Safe Shutter (FSS)

A - 11


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


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


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

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CE REQU

IRED

327.0 (12.87’’)

R280

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REQ

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151.

5 (5

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’)

R185

.0 (7.

28’’)76


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


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)


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


Connector C

12345678910

ScreenN/CRedBlueGreenYellowN/CN/CWhiteBlack

ScreenN/CSys OK Relay COMSys OK Relay NORS485 D1RS485 DØN/CN/CSys OK Relay NCRS485 COM


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


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


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

Blank

B - 1


User Guide

Model 4400

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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3

4

5

6


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.

B - 3


User Guide

Model 4400

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


User GuideB - 4

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

B - 5


User Guide

Model 4400

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


User GuideB - 6

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

B - 7


User Guide

Model 4400

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.

1

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2

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User GuideB - 8

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.

1

4

2

3

B - 9


User Guide

Model 4400

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


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 .

B - 11


User Guide

Model 4400

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


User GuideB - 12

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.

B - 13


User Guide

Model 4400

Note

ThedefinitionofRegisterNumbersgivenintheModbusstandardcancauseconfusion.Forhistoricalreasons,Registersaregivendecimalnumbersbeginningat1,butRegister1islocatedatAddressOffset0.Registernumbersarealwaysonegreaterthantheirassociatedbusaddresses.TheTablebelowusesRegisterNumbers.

ScalingIn the following table, the value in the Modbus register must be divided by thescalingfactortoobtaintheactualvalue.


User GuideB - 14

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

B - 15


User Guide

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


User GuideB - 16

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.

1

2

B - 17


User Guide

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


User GuideB - 18

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


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.

B - 19


User Guide

Model 4400

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


displayed and press

4) Use the and arrows to select Settings and press


User GuideB - 20

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


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


displayed 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.

B - 21


User Guide

Model 4400

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


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

C - 1


User Guide

Model 4400

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.


User GuideC - 2

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.

C - 3


User Guide

Model 4400

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.


User GuideC - 4

Model 4400

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.

5

128

467 3

9

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User Guide

Model 4400

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

D

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User Guide

Model 4400

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


User GuideD - 2

Model 4400

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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User Guide

Model 4400

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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Model 4400

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.


User GuideE - 2

Model 4400

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.

E - 3


User Guide

Model 4400

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.


User GuideE - 4

Model 4400

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.

E - 5


User Guide

Model 4400

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.


User GuideE - 6

Model 4400

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

E - 7


User Guide

Model 4400

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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User Guide

Model 4400

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.


User GuideF - 2

Model 4400

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: [email protected] www.ametek-land.com

AMETEK Land - Americas 150 Freeport Road, Pittsburgh, PA 15238, U.S.A. Tel: +1 (412) 826 4444Email: [email protected] www.ametek-land.com

AMETEK Land China Service Part A1 & A4, 2nd Floor #1 No. 26 Fute 3rd Road East, Pilot Free Trade Zone 200131 Shanghai, China Tel: +86 21 5868 5111 ext 122Email: [email protected]

AMETEK Land India Service Divyasree N R Enclave,Block A, 4th Floor, Site No 1, EPIP Industrial Area Whitefield, Bangalore- 560066 Karnataka, India Tel: +91 - 80 67823240 Email: [email protected] www.ametek-land.com

Documents

Model 4400 User Guide - Publication Nº 813263 - AMETEK Land