Dwyer PMT User Manual

Bulletin J-24

Particu late Moni toring Sys te m s

PMT

Particulate Transmitter

PMT Series

INSTALLATION & OPERATING

MANUAL

Dwyer Instruments, Inc.

102 Indiana Highway 212 P.O. Box 373 Michigan City, IN 46361 USA Telephone 800-872-9141

www.dwyer-inst.com

Particulate Monitoring Systems Installation & Operati ng Manual

I. Technical Support & Return Procedure

Dwyer Instruments, Inc. provides industry leading technical support for all product lines. The technical support department is staffed with a team of engineering professionals.

Areas of assistance provided by the Technical Support department include:

• Product Installation

• General Operation

• Application Specific

• Routine Calibration

• EPA Compliance

• Performance Upgrades and Add-On Features

To ensure the best and most efficient technical support please be prepared with the following information prior to contacting Dwyer Instruments, Inc. If it is determined that the component must be returned for evaluation/repair, a Return Material Authorization number will be issued. You must include the RMA number on the packing slip and mark the outside of the shipping container.

• Company Name ________________________________________

• Product Model Number ________________________________________

• Product Serial Number ________________________________________

• Date of Installation ________________________________________

• Reason for Return ________________________________________

Dwyer Instruments Technical Support may be reached by:

Phone: (800) 872-9141

Fax: (219) 872-9057

E-Mail: tech@dwyer-inst.com

Hours of Operation: 8AM – 5PM Central Standard Time

• Any control unit or particulate sensor that was exposed to hazardous materials in a process

must be properly cleaned in accordance with OSHA standards and a Material Safety Data Sheet (MSDS) completed before it is returned to the factory.

• All shipments returned to the factory must be sent by prepaid transportation.

• All shipments will be returned F.O.B. factory.

• Returns will not be accepted without a Return Material Authorization number.

Particulate Monitoring Systems Installation & Operati ng Manual

II. Notifications

This document contains important information necessary for proper operation of the product. It is strongly urged that all users of the product read this manual in its entirety. All instructions should be followed properly and any questions that arise should be discussed with Dwye r Instruments, Inc .

Any use or distribution of this document without the express consent of Dwyer Instruments, Inc. is strictly prohibited. Any reproduction is prohibited without written permission.

In no event will Dwyer Instruments, Inc. be liable for any mistake, including lost profits, lost savings, environmental compliance costs or other incidental or consequential damages arising out of the use or inability to use this manual, even if advised of the possibility of such da mages, or an y claim b y any oth er par ty.

Identifies information about practices or circumstances that can lead to personal

injury or death, property damage, or economic loss.

Warning statements help you to:

• Identify a hazard

• Avoid a hazard

• Recognize the consequences

Identifies information that is critical for successful application and

IMPORTANT

Identifies information, sections or statements in this manual that apply to

understanding of the product.

approved hazardous area systems, regulations or installation.

Particulate Monitoring Systems Installation & Operati ng Manual

III. Approvals and Certifications

CE Conformant

The Electronics and Particulate Sensors conform to the appropriate country standards and governing regulations listed below:

EN 55011/2002 Limits and methods of measurement of radio interference

characteristics of industrial, scientific and medical equipment. Group 1, Class A.

EN61000-6-2/2001 Electromagnetic compatibility – Generic immunity standard Part 6-2:

Industrial environments.

EN61000-4-2/2000 Electrostatic discharge (ESD), 4kV contact discharge, 8kV air

discharge, 4kV horizontal and vertical coupling planes.

EN61000-4-3/2002 Radiated electromagnetic fields, 10V/m, 80-1000Mhz.

AC line isolation for the Particulate Transmitter must be provided by an external isolating DC power supply with CSA or UL marking. No power supply is provided with or sold as an accessory.

CSA Certified

This Particulate Monitoring system is certified by the Canadian Standards Association (to US and Canadian Standards) for use in hazardous locations as is specified below:

Hazardous Locations

Class I, Division 2 Groups A, B, C, and D

Class II, Division 2 Groups F, G

Class III

Document No. 209-1026-E

Particulate Monitoring Systems Installation & Operati ng Manual

IV. Specifications

ELECTRICAL

PARAMETER DETAIL SPECIFICATION NOTE

Measurement Units picoamperes (pA) 1 x 10 ⎯ ¹² Amp

Standard 10.0pA – 5000pA Measurement Range Optional 5.0 and 0.5pA – 5000pA

Accuracy ± 5% of Range Full Temp Range

Operating -15F to +160F (-25C to +70C) Ambient Temperature Range Digital Filtering Range Ajustable 0.5 Sec – 60 Sec

4-20mA Output

Process Temperature Range

Pressure Range Operating Full Vacuum to 10PSI Other, consult

Particle Concentration (Approximate Guide)

Particle Velocity 300 ft/min. (91 m/min.) and Higher Particle Size 0.3 Micron and Higher

Storage -40F to +185F (-40C to +85C)

Isolation 500VDC Process to Loop

Output

Compliance

Scale Linear or Logarithmic

pA Range 0-100, 0-500, 0-1000, 0-5000 Linear

Standard ½” NPT Mount Mounting

Optional Tri-clamp, Flange

Sensor Teflon over Stainless Materials

Body Stainless Steel

Operating

Type Painted Cast Aluminum Enclosure

Rating NEMA 4X (IP 66)

OPERATING and APPLICATION RANGE

10.0pA

5.0pA

Optional

0.5pA

Optional

Max. RLoad = (Vsupply–18V)/0.02A (24VDC = 300Ohm Rload Max.)

0.5–500, 5–5000 Logarithmic

MECHANICAL

-40F to +250F (-40C to +120C)

-40F to +450F (-40C to +232C)

-40F to +800F (-40C to +427C) two piece

At least 10.0-5000 mg/m³ At least 0.004 to 2.0 gr/cf At least 5.0 – 5000 mg/m³ At least 0.002 to 2.0 gr/cf At least 0.5 to 500 mg/m³ At least 0.0002 to 0.2 gr/cf

Other, consult factory

configuration only

factory

Visible

Barely Visible To Visible Barely Visible To Invisible

Document No. 209-1026-E

Particulate Monitoring Systems Installation & Operati ng Manual

V. Installation Drawings

Drawing Number Sheets Description

225-1032 2 Installation Drawing

225-1036 1 High Temperature / High Pressure Particulate Flow Sensor

Installation Drawing

Document No. 209-1026-E

Particu late Monitoring Sys te m s Installation & Operating Manual

TABLE OF CONTENTS

Safety...............................................................................................................................................2

1.1 Applicable Use.......................................................................................................................... 2

1.2 General..................................................................................................................................... 2

1.3 Hazardous Area Systems........................................................................................................... 3

2. Introduction.................................................................................................................................... 4

3. Comp onent Description.................................................................................................................. 5

3.1 One-p iece Config uration............................................................................................................ 5

3.2 Two-piece Configuration with Remote Electronics ....................................................................5

3.3 Particulate Sensor/Probe............................................................................................................ 6

3.4 Smart Transmitter Modu le.........................................................................................................6

3.5 Coaxial Cable for Particulate Sensor .......................................................................................... 6

3.6 Sensor Test Port (Non -Hazardous Areas Only) ..........................................................................6

4. Particulate Sensor Installation........................................................................................................7

4.1 Location.................................................................................................................................... 7

4.2 Mounting....................................................................................................................... ........... 8

4.3 Senso r Te mperature Considerations........................................................................................... 9

5. Control Unit Installation...............................................................................................................10

5.1 Location.................................................................................................................................. 10

6. Smart Transmitter Wiring............................................................................................................ 11

6.1 Groun ding ............................................................................................................................... 11

6.2 4-20mA Wiring....................................................................................................................... 11

6.3 Sensor Cable Installation – T wo piece config u r ation onl y......................................................... 12

7. Startup .......................................................................................................................................... 13

7.1 4-20mA Loop Ch eck...............................................................................................................13

7.2 System Zero Check .................................................................................................................14

8. Interpreting Readings and Adjusting 4-20mA Range..................................................................17

8.1 Fabric Filter (Baghouse) Applications...................................................................................... 17

8.2 Alarm Levels for Fabric Filter Applications............................................................................. 18

8.3 4-20mA Output Range Adjustment .......................................................................................... 20

8.4 Time-constant Adjustment....................................................................................................... 21

9. Routine Maintenance....................................................................................................................22

10. Troubleshooting............................................................................................................................ 23

11. Spare Parts.................................................................................................................................... 24

Particu late Monitoring Sys te m s Installation & Operating Manual

1. Safety

1.1 Applicable Use

These particulate monitor systems ar e not designed for use as a functional safety device and do not carry a SIL rating. The device m ust not be used as part of a safety syst em or as an input signal to a safet y system. Th ese monitors ar e designed for general proce s s and envir onmental monitoring.

1.2 General

This apparatus is available with various agency approvals as noted in the approvals section. All versions of this device have been designed to comply with EN 61010, safety requirements for elec tric al equipment for measu rement, control a nd laboratory use, and are s u p plied in a safe co ndition. Before beginning an in stallation the following safety precautions and all precaution s throughout this manual and in the ins tallation dr awings mu st be followed.

AREA CLASSIFICATION

• Before installing any device confirm area classification requirements. Do

not install any device that is not tagged as suitable for the required area classificati on .

• WARNING – Substitution of components may impair suitability for

Division 2 hazardous loc ations.

PROCESS AND AMBIENT CONDITIONS

• Before installing any device, confirm ambient temperature, process

temperature and process pressure requirements. Do not install any device that is not tagged as suitable for the required temperatures and pressures. Confirm compatibility of the wetted and non -wetted materials.

INSTALLATION PERSONNEL AND SERVICE

• Only appropriately licensed and trained professionals should perform the

mechan ical and el ectrical ins tallation.

• This device does not contain field serviceable components other than th e

line fuse. Only factory personnel can perform service on this equipment.

• For operator safety and to prevent ignition of flammable or combustible

atmospher es always disconnect power before servicing.

GROUNDING AND FUSING

• Before applying power to the instrument, you must connect the sensor

housing and remote electronics housing (two piece configuration) to a pr ope r ear th ground. Th e se n sor hous in g is con n ect e d t o ea rth ground usi n g the ext ernal groun d screw. Th e remot e electr onics h ousing is connect ed to earth ground through the dedicated ground screw inside the housing. Groundin g to the neutral conductor of a single-phase circuit is not sufficient protection.

• Only fuses with the required current, volt age and specified type should be

used. D o n ot u s e r ep aired fuses or short-cir cu ited fuse hol d er s .

Particu late Monitoring Sys te m s Installation & Operating Manual

REGULATORY CODES

• Installation and operation must adher e to all national and local codes.

1.3 Hazardous Area Syste ms

Systems approved for use in hazardous areas include nameplates indicating that they are suitable for inst allation in hazard ou s areas. The nameplate lists allowable hazardous areas and T code ratings as well as approval agen cy markings. Do n ot in stall any device that is not tagged as suitable for the area classifica tion.

Section s or st at emen ts in thi s man ua l tha t a pply to a pproved ha zar dous ar ea syst ems or in s tall ati on s are designated with the following symbol. Designation for use in hazardous areas does not make the system su itable for use as a function al safety device.

HAZARDOUS AREAS

• WARNING – Substitution of components may impair suitability for

Division 2 hazardous loc ations.

• Installation mu st be in accord ance with ANS I /I S A RP1 2 .6 and Nati onal

Electric Code ANSI/NFPA 70, Article 504

• Do not connect or disconnect components unless power has been

disconnected.

• Designation for use in hazardous areas does not make the system

suit able for use as a fun ctional sa fety device.

Particulate Monitoring Systems Installation & Operati ng Manual

2. Introduction

A Parti culate Mon itorin g System con sist s of a contr ol unit, a par ticul ate sensor and a sen sor coaxia l cable. Applications include continuous emissions monitoring, baghouse filter leak detection and process particulate flow monitoring. Types of particulate include both solid particulates (dusts, powders, granulars, and pellets) and liquid particulates (mists). Various control unit models and sensors are pr ovided to match the application an d process monitoring needs.

Principle of Operation

Particulate Monitoring Systems employ a highly reliable technology based on induction. A sensor probe is mounted in an airflow stream such as a pipe, duct or stack (for small tubing an inline nonintr usive ring sen sor is employed). As particul ate flows near and over the sen sing element, m inute electr ical cur rents ar e induced in th e sensor an d transfer red to th e control unit by a coa xial cable. A microprocess or filter s and pr ocesses the signal into a normalized, absolute output that is linear to the mass concentrat ion of particu late.

_ MASS CORRELATION

IMPORTANT

It is important to note that the above relation between instrument units (pA) and actual mass (mg/m appropriate model and range and for providi ng a general indic ation of the typic al particulate levels monitored. For a true correlation between (pA) and actual mass (mg/m must be performed for each application and a recommended model and detection level must be ordered. It is also important to note th at the accuracy of such correlations is application dependent and produces the best results with consistent particulate and process conditions. The user must follow proper procedures and must understand the typical accuracy of such correlation techn iques. Consult factor y for details.

or gr/cf) is just an approximate guide for selecting the

or gr/cf), a gravimetric correlation such as an isokinetic sample

Particulate Monitoring Systems Installation & Operati ng Manual

3. Component Description

One and two pi ece vers ion s of t h e par ti cula t e tran smit t er ar e ava ila ble wi th var ious pr obe lengths and mounting configurations. The standard configuration features the smart transmitter module integrated directly into the sensor connection housing. A two-piece configuration incorporates a separate enclosu re for th e smar t transmitt er module, a remote sensor/probe and an in terconnect ing cable.

3.1 One-piece Configuration

(Example only, mounting and probe length variable)

3.2 Two-piece Configuration with Remote Electronics

(Example only, mounting and probe length variable)

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