Bulletin J-24 Particulate Monitoring Systems 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.
Particulate Monitoring Systems Installation & Operating 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.
Particulate Monitoring Systems Installation & Operating 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 Dwyer Instruments, Inc. Any use or distribution of this document without the express consent of Dwyer Instruments, Inc. is strictly prohibited.
Particulate Monitoring Systems Installation & Operating 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.
Particulate Monitoring Systems Installation & Operating Manual IV. Specifications ELECTRICAL PARAMETER Measurement Units Measurement Range Accuracy Ambient Temperature Range Digital Filtering 4-20mA Output Mounting Materials DETAIL Standard Optional Operating Storage Range Isolation Output Compliance Scale pA Range Standard Optional Sensor Body Operating Process Temperature Range SPECIFICATION picoamperes (pA) 10.0pA – 5000pA 5.0 and 0.
Particulate Monitoring Systems Installation & Operating 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.
Particulate Monitoring Systems Installation & Operating Manual TABLE OF CONTENTS 1. Safety............................................................................................................................................... 2 1.1 1.2 1.3 Applicable Use.......................................................................................................................... 2 General .................................................................................................................
Particulate Monitoring Systems Installation & Operating Manual 1. Safety 1.1 Applicable Use These particulate monitor systems are not designed for use as a functional safety device and do not carry a SIL rating. The device must not be used as part of a safety system or as an input signal to a safety system. These monitors are designed for general process and environmental monitoring. 1.2 General This apparatus is available with various agency approvals as noted in the approvals section.
Particulate Monitoring Systems Installation & Operating Manual REGULATORY CODES • 1.3 Installation and operation must adhere to all national and local codes. Hazardous Area Systems Systems approved for use in hazardous areas include nameplates indicating that they are suitable for installation in hazardous areas. The nameplate lists allowable hazardous areas and T code ratings as well as approval agency markings. Do not install any device that is not tagged as suitable for the area classification.
Particulate Monitoring Systems Installation & Operating Manual 2. Introduction A Particulate Monitoring System consists of a control unit, a particulate sensor and a sensor coaxial 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).
Particulate Monitoring Systems Installation & Operating Manual 3. Component Description One and two piece versions of the particulate transmitter are available with various probe 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 enclosure for the smart transmitter module, a remote sensor/probe and an interconnecting cable. 3.
Particulate Monitoring Systems 3.3 Installation & Operating Manual Particulate Sensor/Probe The particulate sensor consists of a stainless probe with a non-conductive protective layer or coating, a stainless steel nipple/mount and the sensor housing. It is a very rugged assembly that is virtually maintenance-free. It does not require special alignment, is not affected by normal vibration and does not require cleaning. 3.
Particulate Monitoring Systems Installation & Operating Manual 4. Particulate Sensor Installation The following applies for both one and two piece configurations. 4.
Particulate Monitoring Systems Installation & Operating Manual It is essential for the pipe/duct to provide an electrical (Faraday) shield for the sensor. It is therefore required that the pipe, duct or stack is metal and earth grounded (small inline tubing sensors provide their own section of metal pipe which also must be grounded). Consult the factory when insertion probe style sensors are to be installed in non-conductive pipes, ducts such as plastic or fiberglass.
Particulate Monitoring Systems 4.3 Installation & Operating Manual Sensor Temperature Considerations The sensor may be ordered with one of three process temperature ranges: 1. -40ºF to 250ºF (-40ºC to 121ºC) 2. -40ºF to 450ºF (-40ºC to 232ºC) 3. -40ºF to 800ºF (-40ºC to 426ºC) Note: For the process temperatures in the range of 233ºC - 426ºC, a high temp probe must be used. The maximum allowable ambient temperature at sensor housing is 70ºC.
Particulate Monitoring Systems Installation & Operating Manual 5. Control Unit Installation The following applies for two-piece configurations only. 5.
Particulate Monitoring Systems Installation & Operating Manual 6. Smart Transmitter Wiring 6.1 Grounding Proper grounding is essential to ensure reliable operation and operator safety. CONTROL UNIT GROUNDING For One-Piece configurations: • Connection to protective ground is made through the process mount. Protective earth ground connection to external ground screw must be installed when mounted to non-metallic or ungrounded process. For Two-Piece configurations: 6.
Particulate Monitoring Systems 6.3 Installation & Operating Manual Sensor Cable Installation – Two piece configuration only Connection: Prior to making coaxial cable connections review the following routing instructions. IMPORTANT _ PARTICULATE SENSOR COAXIAL CABLE ROUTING • The sensor cable must be installed in conduit that is separate from all other wiring.
Particulate Monitoring Systems Installation & Operating Manual 7. Startup 7.1 4-20mA Loop Check Upon initial installation the 4-20mA loop connection should be tested. Monitor the transmitter’s mA output with a multimeter connected in series with the 4-20mA loop or monitor the PLC register or measuring device. Step 1: Check the transmitter’s 4mA output by setting the output range switch to the “4mA Test” position. The output should be 3.9mA – 4.1mA.
Particulate Monitoring Systems 7.2 Installation & Operating Manual System Zero Check The System Zero Check is used at installation to confirm proper installation and for troubleshooting. SAFETY • Always disconnect power to the control unit before making any wiring changes at either the control unit or sensor as well as when making any mounting changes or replacing any component.
Particulate Monitoring Systems Installation & Operating Manual Control Unit Zero Check 1. Disconnect power to the control unit. 2. For a two piece configuration, open the enclosure cover and unscrew the coaxial cable connector from the control unit. Leave the connector inside the control unit enclosure. Make sure the connector does not slip down into the conduit.
Particulate Monitoring Systems Installation & Operating Manual Pass: 1. Disconnect power to the control unit. 2. Open the sensor enclosure cover and re-attach the coaxial cable center conductor to the sensor probe end. 3. Close the sensor enclosure cover and proceed to the sensor zero check. Fail: 1. Check cable installation and routing instructions in the Installation section of this manual for proper cable installation. Make any changes necessary. 2. Contact the factory for further assistance.
Particulate Monitoring Systems 8. 8.1 Installation & Operating Manual Interpreting Readings and Adjusting 4-20mA Range Fabric Filter (Baghouse) Applications Particulate flow is very dynamic in nature, thus the output signal is also usually very dynamic. This is more often the case with fabric filter and dust collection exhaust monitoring applications where filter emissions and filter cleaning systems can cause wide ranging variations in the particulate levels.
Particulate Monitoring Systems 8.2 Installation & Operating Manual Alarm Levels for Fabric Filter Applications In fabric filter applications it is common to use alarms for indicating sustained high readings. Internal alarms are not included in 4-20mA loop powered transmitter products. Alarming for loop powered transmitter products is typically a part of an external system such as a PLC or Plant Wide Control System. It is recommended to set two separate alarm levels.
Particulate Monitoring Systems _ IMPORTANT Installation & Operating Manual ALARM LEVELS FOR EPA COMPLIANT LEAK DETECTION • Alarm levels for EPA compliant leak detection such as MACT regulations should initially be set as low as possible until sufficient trend data has been logged and all considerations have been made. • Do not increase the alarm levels without proper justification.
Particulate Monitoring Systems 8.3 Installation & Operating Manual 4-20mA Output Range Adjustment For proper selection of 4-20mA output range, both baseline and peak levels must be taken into account. The 4-20mA output range should be selected to allow accurate measurement of low baseline signals while still allowing resolution of higher peak signals that occur during pulse-jet cleaning cycles. The 4-20mA analog output represents the linear or logarithmic equivalent of the “pA” particulate levels.
Particulate Monitoring Systems Installation & Operating Manual Linear Scale: Linear scaling provides direct, proportional, linear change in the 4-20mA output signal over the selected pA range. Allowable ranges are 0-100pA, 0-500pA, 0-1000pA, and 0-5000pA. To convert the 4-20mA linear signal back into pA in the remote plc/dcs, the following formula is used: pA = Measured (mA) − 4.0(mA) * Range( pA) 16.
Particulate Monitoring Systems Installation & Operating Manual 9. Routine Maintenance EQUIPMENT MAINTENANCE • Only appropriately licensed professionals should perform maintenance on this product. • WARNING – To prevent ignition of flammable or combustible atmospheres and for operator safety, always disconnect power before servicing. Particulate Sensor: The sensor does not normally need any cleaning and for optimal performance, routine cleaning of the sensor is not recommended.
Particulate Monitoring Systems Installation & Operating Manual 10. Troubleshooting The most important aspects of troubleshooting are to keep in mind the instrument is monitoring small signals. The quality of cable connectors should not be overlooked. The sensor housing should be kept dry and clean. Break all troubleshooting down into the basic system components, the sensor, smart transmitter module and 4-20mA loop. False High Signals (False Alarms) 1.
Particulate Monitoring Systems Installation & Operating Manual 11. Spare Parts Item Details Part No. Control Unit/Transmitter Control Unit/Transmitter Family Refer to Product Label Particulate Sensor Variable Lengths & Connections Refer to Product Label Particulate Sensor Cable Coax, SMA x Ring Lugs Document No.
Particulate Monitoring Systems Installation & Operating Manual Notes: Document No.
