SM-202M Ins Manual V1.5A
SM-202M Ins Manual V1.5A
SM-202M Ins Manual V1.5A
www.dynoptic.com
DynOptic Systems Ltd – Furlong House, Crowfield, Brackley, Northamptonshire, NN13 5TW United Kingdom
All technical details and specifications are subject to change without notice
SM-202M Smoke Opacity Monitor – Installation Manual
Contents
Contents .......................................................................................................... 2
Warnings .......................................................................................................... 3
General Warnings ........................................................................................ 4
Product Overview............................................................................................. 6
Revision Control............................................................................................. 28
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SM-202M Smoke Opacity Monitor – Installation Manual
Warnings
Throughout the manual the following symbols are used to highlight the
potential dangers when installing, operating and servicing the instruments.
Recycle Responsibly.
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SM-202M Smoke Opacity Monitor – Installation Manual
General Warnings
Each section of the manual outlines the specific warnings for that part of the
process or procedure. Below are some general guidelines that should be
followed at all times:-
• All electrical work must be carried out with the power to the
instrument OFF i.e. it must be isolated from any source of
voltage. Failure to do so could result in equipment failure, injury
or death.
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SM-202M Smoke Opacity Monitor – Installation Manual
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SM-202M Smoke Opacity Monitor – Installation Manual
Product Overview
The SM-202M Smoke Opacity Monitor measures open path light transmission
using a transmitter (TX) and receiver (RX) system. They are typically installed
on a duct, stack, or flue for the purpose of monitoring increases in Opacity (0-
100%) or Particle Density (mg/m3) caused by suspended particles (e.g. dust
and smoke) passing through the light path.
The TX and RX are mounted opposite each other across the stack so that the
light beam generated in the TX passes across the centre of the duct (through
the gas stream) and falls directly onto the RX on the other side. The
instrument measures changes in the intensity of the received light caused by
suspended particulates in the gas stream. This measurement may be used
directly, or in conjunction with calibrated scale factors, to generate a reading
in a choice of units.
Both the TX and RX heads are supplied with cast aluminium air-purges, these
not only provide the physical mounting point for the instrument, but also allow
users to connect an appropriate air supply to help keep the optics clean and
prolong service intervals.
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SM-202M Smoke Opacity Monitor – Installation Manual
It’s very important that the installation of your SM-202M is planned out
carefully in advance. Please study this section carefully and ensure that you
have taken proper advice on local and national regulatory requirements
before starting your installation. Proper planning will avoid the need for
modification to your installation at a later date.
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SM-202M Smoke Opacity Monitor – Installation Manual
- Vibration and angular movement will cause the light beam to move and
may result in an unstable opacity measurement. Therefore the heads must be
mounted securely on a sturdy section of the duct or stack that will not be
prone to high levels of vibration. If the duct wall is thin and flexible, it should
be reinforced at the mounting position, or a frame should be constructed to
hold both heads stable in relation to one another. You must ensure that the
angular relationship between the TX and RX heads remains constant in all
conditions. Pay particular consideration to the possibility of vibration, and also
expansion and contraction of local structures with temperature.
Where suitable sample planes exist in both vertical and horizontal sections of
the duct, the vertical section is preferable.
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SM-202M Smoke Opacity Monitor – Installation Manual
Note: The heads should never be positioned top and bottom of a horizontal
duct or angled duct, as particle matter will fall under gravity into the bottom
head and cause the optics to become dirty more quickly.
- Mist, spray, droplets, and condensing liquids will affect the light in a
similar way to the dust or smoke particles. In most installations it is
undesirable to measure the contribution from liquid droplets and therefore a
mounting location should be chosen that is free from such contaminates.
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SM-202M Smoke Opacity Monitor – Installation Manual
If the heads are mounted on a vertical stack section near to the exhaust point,
there is the possibility that heavier droplets (from rain or condensing steam)
may fall down into the stack, against the direction of the gas flow. These
droplets will also generate an opacity reading, which may be undesirable, and
an alternative location should be considered.
The mounting flange face temperature must not exceed 200°C and the
standard installation recommendations provided in this manual are for a
maximum stack gas temperature of 600°C. Please consult DynOptic Systems
if the application has stack gas temperatures higher than 600ºC.
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SM-202M Smoke Opacity Monitor – Installation Manual
The ambient air temperature around the heads should be in the region -20°C
to +50°C.
If the ambient air temperature around the head is being affected by radiated
heat from the duct, the use of rock wool lagging on the duct, or a heat shield
in front of the heads, may be necessary.
Where the heads are mounted externally they should be shielded from direct
sunlight at all times. The heads may be mounted under a canopy or shelter, or
alternatively an optional weather cover is available from DynOptic Systems.
The length of the cable between the OI and the RX is limited by the voltage
drop likely to occur on the ±15Vdc supply carried in this cable (maximum
recommended length 100m). Always calculate the potential voltage drop
when specifying the type/length of this cable. The ±15Vdc supply to the RX
must not fall below ±12Vdc.
The cable route should ideally be independent of other plant cabling, and
SM-202M cables must not be laid alongside anything which may emit
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SM-202M Smoke Opacity Monitor – Installation Manual
Tight bends, pinching, clamping, and the possibility of wear or abrasion must
also be avoided when choosing the route.
- Earth connections are required on both heads protect the electronic circuit
boards inside the TX and RX heads from the effects of Electro Static
Discharge (ESD) and high voltage transients.
If the heads are not directly earthed, any local ESD or high voltage surge is
likely find a path to earth through the sensitive circuit boards inside the heads,
inevitably causing damage. However, if the heads are properly earthed, that
same ESD, or surge, would find its way back to earth through the proper
electrical earth connection, instead of through the electronic.
A location for the heads must be chosen where a proper electrical earth is
available. It is not acceptable to rely on the stack or the mounting flanges as
an earth point.
- Summary: A location for the heads must be chosen with consideration to all
the points above. If it is impossible to satisfy all the recommended criteria
please make a sensible compromise rather than disregard one point
altogether.
The TX and RX heads must be mounted directly opposite each other across
the stack or duct, so that light from the TX passes through the centre of the
duct and falls directly onto the RX.
Each head should be bolted to a suitable mounting flange (1.5” ANSI 150
pattern) extended away from the side of the stack on a short extension tube.
See below for the required construction details of a suitable mounting flange
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SM-202M Smoke Opacity Monitor – Installation Manual
An excellent way to ensure that the mounting flange extensions meet the
required angular and linear alignment tolerances, is to insert a straight pole or
tube through the stack (so that it protrudes either side of the stack), and then
slide the mounting flange extensions over the protruding pole/tube on each
side, before welding the flange extensions in place on the stack. This
technique will ensure that the mounting flanges are well aligned as they are
welded in place. See below for an example of the technique.
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SM-202M Smoke Opacity Monitor – Installation Manual
When fitting the mounting flange, the extension tube should pass through the
wall of the stack and protrude slightly (~50mm) into the duct. The purpose of
the intrusion is to prevent any dirt or slime build-up on the inner wall of the
duct falling down the wall and passing through the light path.
Keep the flange extension tube as short as possible whilst maintaining the
minimum clearance between the mounting flange and the stack wall and/or
the insulation, as shown below.
The flange extensions should be installed with the bolt holes at 45° to the
vertical, as shown below.
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SM-202M Smoke Opacity Monitor – Installation Manual
Each SM-202M air-purge body has four (4) threaded M14 holes on a PCD to
match the mounting flange. The bodies can be installed on the mounting
flange either by inserting a bolt from the stack side of the flange, or by fitting
short lengths of threaded stud into the air-purge head and securing them from
the stack side of the flange with matching nuts. The nuts or bolts will be
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SM-202M Smoke Opacity Monitor – Installation Manual
Select bolts and studs of a suitable length, and remember to allow for the
additional thickness of the rubber alignment gaskets, heat insulating gaskets,
washers, and any weather shield that may be fitted as part of the installation.
A fixing kit containing suitable M14 studs, washers and nuts is available from
DynOptic Systems.
The instrument is supplied with four (4) heat insulating gaskets manufactured
from a 6mm thick woven ceramic fibre cloth (white in colour). Two (2) of these
gaskets must be installed on each side of the stack. They must be installed as
shown below, so that they are installed against the hot mounting flange
surface, and will therefore protect the red silicone rubber alignments gaskets,
and the TX/RX heads from conducted heat from the flange face.
The instrument is supplied with two (2) red silicone rubber alignment gaskets
which must be fitted as shown below, so that they are protected from the heat
of the mounting flange by the heat insulating gaskets. These rubber alignment
gaskets will allow for a degree of adjustment to be made in the angular
alignment of each head during commissioning. The alignment gasket must not
come into contact with any surface that has a temperature in excess of 150°C.
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SM-202M Smoke Opacity Monitor – Installation Manual
Earth connection
It is important that both head enclosures are bonded to a local electrical earth.
This protective earth connection must be made off to the M5 stud on the
outside of each of the head enclosures, as indicated below.
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SM-202M Smoke Opacity Monitor – Installation Manual
Air-Purge System
The air-purge system achieves this by producing a flow of clean and dry air
flowing away from the head and into the stack. This air-flow provides a clean
air barrier between the optics and the stack gas.
• A clean, dry, purge air supply which could be derived from a suitably
filtered air blower or pressure regulated and filtered compressed air
(not supplied).
• Hose and fittings necessary to connect the air supply to the heads
(not supplied)
The air-purge bodies are supplied with the instrument; all the other elements
are available as accessories. For more information on the available options
and technical specifications required, please refer to the ‘Purge Air
Requirements’ document.
Note: We recommend that flexible hose is used. The use of non-flexible hose
can affect the ability to align the heads.
Note: Due to the possibility of damage to the heads if the purge air fails or is
turned off; a failsafe shutter is available from DynOptic Systems.
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SM-202M Smoke Opacity Monitor – Installation Manual
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SM-202M Smoke Opacity Monitor – Installation Manual
Fixing the OI
The OI is designed to be inserted into a master control panel. The master
control panel needs to be prepared with a suitable cut-out detail to accept the
OI. The cut-out detail consists of a main rectangular aperture, through which
to pass the body of the OI, and four (4) surrounding through holes with which
to secure the OI in place.
The OI should be inserted into the master panel and then secured using M5
screws and nuts. The OI is supplied with a thin rubber gasket which should be
fitted between the OI and the master panel to form a dust tight seal.
The ambient air temperature around the OI should be in the region -20°C to
+55°C.
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SM-202M Smoke Opacity Monitor – Installation Manual
Earth connection
It is important that the front panel is bonded to a local electrical earth. This
protective earth connection must be made off to the M5 stud on the back of
the front panel, as indicated below.
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SM-202M Smoke Opacity Monitor – Installation Manual
The cable connecting the OI to the RX must have a minimum of 6 cores, and
be no longer than 100m and meet the specification shown below.
All cables must have an individual core size of between 0.518mm² (20AWG)
and 2.08mm² (14AWG).
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SM-202M Smoke Opacity Monitor – Installation Manual
All cables must be screened, ideally individually screened twisted pairs, with a
common drain wire, such as Belden 9873 (6 core, screened pair, 20AWG).
The SM-202M cables carry sensitive electronic signals which can be affected
by RFI and EMI, so care should be taken to run the cables away from high
voltage power cables, high frequency signal cables, or switch gear cabling.
The supplied ferrite tubes must be fitted on the cables where the cables enter
the TX, RX, or OI enclosures. The ferrites should be secured in place so that
they remain fixed adjacent to the cable gland entry, as shown in the examples
below.
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SM-202M Smoke Opacity Monitor – Installation Manual
All cables entering the TX, RX, or OI must do so through the cable glands
provided. All cable glands must be fully tightened onto the cable to maintain
the enclosures environmental rating.
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SM-202M Smoke Opacity Monitor – Installation Manual
Any unused cable gland entries should be sealed using the rubber bungs
supplied. Tighten the gland onto the rubber bung to ensure protection.
Note: Please ensure that no wires pass through the optical beam inside the
head enclosure. This can be achieved by checking that no stray wires, or wire
slack enters the area bounded by the 4 pillars that support the circuit board.
Wiring details are covered in the separate electrical wiring details section.
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SM-202M Smoke Opacity Monitor – Installation Manual
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SM-202M Smoke Opacity Monitor – Installation Manual
The following page shows a complete installation wiring diagram for the
SM202M.
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SM-202M Smoke Opacity Monitor – Installation Manual
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SM-202M Smoke Opacity Monitor – Installation Manual
Revision Control
Revision
Version Date Revision Details Author
V1.0 08/10/2013 Original. Dominic Sheedy
V1.1 08/11/2013 Drawing updates. Dominic Sheedy
V1.2 15/01/2014 Update wiring diagram and protective earth requirements Jason Lupe
V1.3 29/01/2014 Change text “Earth Connections” text on page 12 Paul Jones
V1.4 12/02/2014 Spelling error corrected on page 27. Dominic Sheedy
V1.5 08/10/2014 Add ambient temperature statement for OI Paul Jones
All technical details and specifications are subject to change without notice
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