DUST DETECT 1000 MANUAL
Contents
1. Taking Control To A Higher Level MODEL DD1000 DUST DETECT INSTALLATION AND OPERATING INSTRUCTIONS READ THOROUGHLY BEFORE INSTALLING Em Am uu mm umb EA Ee UN ANS UA Ay uv ETD 2 4 a Division of Garner Industries 7201 No 98th Street P B Lincoln N Box 29709 8507 Lincoln NE 68529 402 434 9102 Fax 402 434 9133 www binmaster com 9250126 FM INTRODUCTION The DD1000 is a single piece dust detector that has been specifically designed to be easily set up to monitor particulate emissions from small stacks and emission points The DD1000 is able to recognize abnormal operation of the plant and is able to initiate alarms when changes in emissions exceed user defined limits The DD1000 utilizes turboelectric technology whereby the collision and interaction of particles with the probe rod causes a small electrical charge transfer to occur between the particulate and the probe rod This small electrical charge provides the signal that is monitored by the electronics If the material type remains constant the signal generated is proportional to the dust concentration even if an accumulation of dust forms on the sensor rod INSTALLATION amp MOUNTING OF DD1000 The best position for the DD1000 is a section of ductwork where the particulate has an even distribution and the flow is linear This would ideally be in a vertical or horizontal section of duct having no bends or obstructions for at least th2. WHERE THE LED CHANGES TO FLASHING RED THEN TURN IT BACK CLOCKWISE TO THE NEXT CLOSEST MARKING THE LED SHOULD AGAIN BE FLASHING GREEN SLOWLY ROTATE THE UNITS CONTROL COUNTER CLOCKWISE TO THE POINT WHERE THE LED CHANGES TO FLASHING RED THIS IS THE NORMAL RELATIVE DUST LEVEL AS READ BY THE UNITS NUMBER MULTIPLIED BY THE MULTIPLIER CONTROL VALUE MOVE THE MODE SWITCH TO THE ALM POSITION USING THE UNITS AND MULTIPLIER CONTROLS DIAL IN THE DESIRED ALARM 2 LEVEL THIS SHOULD BE AT LEAST 3 TIMES GREATER THAN THE NORMAL DUST REFERENCE LEVEL SINCE THE ALARM 1 LEVEL IS HALF OF THE ALARM 2 VALUE SET THE RESPONSE SWITCH TO AVG AVERAGE OR INS INSTANTANEOUS AS DESIRED RECONNECT THE RELAY ALARM WIRING IF IT WAS PREVIOUSLY DISCONNECTED 8 Mounting Instructions _ Always Mount Unit with Conduit Opening Down CONDUIT SEAL When installing this level indicator in environments where it is possible for moisture or moist air to enter the enclosure thru the electrical conduit the conduit opening should be sealed with a duct seal compound or putty appropriate for the purpose BINA A mM EN e Ay uv ED 2 A F Division of Garner Industries 7201 No 98th Street P O Box 29709 Lincoln NE 68507 Lincoln NE 68529 402 434 9102 Fax 402 434 9133 www binmaster com
3. then it is recommended to use the averaging mode AVG to lessen the possibility of false triggering of the alarms At this point the set up procedure has been completed Reconnect the terminal headers for CON5 AND CONE If you do not have the 4 20mA option you may replace the enclosure cover and secure it in place with the cover bolts 4 to 20mA OUTPUT OPTION The DD1000 can be equipped with an optional 4 to 20mA output This output provides a current related to the actual dust level being detected by the DD1000 The 4 to 20mA is an isolated output that can drive a maximum loop resistance of 600 ohms A twisted pair cable of at least 22 AWG wire should be used to connect to the receiving instrument Take care to observe output polarity 4 to 20mA SETUP 6 For setup and real time output of the 4 20mA loop place the damping switch in the OFF position The 4 to 20mA PC board uses the unit and the multiplier potentiometers to set up the full scale output of the 4 to 20mA loop See Figure 3 These potentiometers work just like the units and multiplier potentiometers on the DD1000 main board Use the normal dust level value determined during set up of the DD1000 to set up the full scale output of the 4 to 20mA loop The 20mA or 100 output would be set to some multiple of the normal dust level typically the same as the High alarm level was set to To accomplish this simply set the potentiometers on the 4 to 20mA board the same as those on the
4. Main DD1000 board Figure 3 CONI RS dl d aye r0 OFF 2 8 H DAMP i Js DN cow2 Jn 4 20mA P3 LOOP PRI When the 4 to 20mA output is used to drive devices that you do not want to be constantly fluctuating the DAMPING switch on the 4 to 20mA board can be put in the ON position With the DAMPING switch in the ON position the output will be a steady level that is continuously updated at regular time intervals typically less than a minute This is suitable for devices such as chart recorders that would then show timed step changes at short intervals rather than constantly fluctuating indications FCC COMPLIANCE CAUTION This device has been verified to comply with FCC Part 15 Changes or modifications not expressly approved by Garner Industries for compliance could void the user s authority to operate the equipment SUMMERIZED SETUP PROCEDURE PLANT PROCESS MUST BE RUNNING AT NORMAL DUST LEVEL DISCONNECT RELAY OUTPUTS TO PREVENT FALSE ALARMS DISCONNECT POWER FOR AT LEAST ONE MINUTE SET CONTROLS AS FOLLOWS BOTH ALARM CONTROLS FULL CLOCKWISE MODE SWITCH TO ALM RESPONSE SWITCH TO AVG RECONNECT POWER OBSERVE THAT THE LED GOES TO A STEADY COLOR MOVE THE MODE SWITCH TO THE SET POSITION LED SHOULD FLASH GREEN WAIT DESIRED TIME FOR COLLECTING REFERENCE DATA SLOWLY ROTATE THE MULTIPLIER CONTROL COUNTER CLOCKWISE TO THE POINT
5. UP PROCEDURE The DD1000 is setup using the two potentiometers and two slide switches on the main circuit board See Figure 2 Figure 2 CON1 BINMASTER 530 4 56 x10 x100 IST a E 3 7 CY C e id d 1 9 0 10 x1 x1000 CON2A CON7 E NN TRANS1 ALM SET INS AVG MODE RESPONSE NC C NO NC C NO LI N CS ALARM 1 ALARM 2 CONS CON6 CON4 Lt NI RL1 There are five main steps involved in setting up the DD1000 they are Note If you do not wish to trigger an external alarm while setting the DD1000 you should disconnect any connections from the ALARM relay terminals CON5 AND CON6 by unplugging the terminal plugs Step 1 Before applying power set both Alarm Level potentiometers to full clockwise Set the MODE switch to ALM and the RESPONSE switch to AVG Now apply power to the DD1000 After an initial delay of approximately 2 seconds the Alarm status LED DS1 will go to a steady state illumination The color of the LED can be either steady green or red at this point If the LED does not go to a steady color but continues to flash orange after 5 seconds then disconnect power to the unit wait 1 full minute and then apply power again Step 2The purpose of this step is to capture some reference dust level information from the plant It is essential that the
6. e this equates to 1500 2 750 units Care must be taken to ensure that the High alarm level is set to more than TWICE the normal plant dust level otherwise relay 1 will always be in alarm Step 5The purpose of this step is to set the alarm response to the desired setting The Alarm Response of the DD1000 can be set to a time averaging mode by setting the RESPONSE switch to the AVG position or to an instant mode by setting the RESPONSE switch to the INS position When the RESPONSE switch is in the AVG position the DD1000 will average the dust level for two consecutive 30 second time intervals If the average dust level for both 30 second time periods is greater that the set High alarm level then the High Alarm will be triggered Both relays 1 and 2 will de energize and the LED will turn steady RED If the average dust level for both 30 second time periods is greater that HALF of the set High alarm level then the Early Warning Alarm alarm1 will be de energized and the LED will turn ORANGE The DD1000 alarms will stay triggered until the average dust level for a 30 second interval falls below the respective trigger level for each alarm When the RESPONSE switch is in the INS position The DD1000 will trigger the appropriate alarm immediately whenever the dust exceeds the set alarm level Likewise the alarm will cease immediately whenever the dust level is below the set alarm level If you are uncertain about which alarm response you should use
7. plant is running normally during this time i e not during the start up phase and with bag cleaning operating where appropriate To begin collecting information set the MODE switch to SET The Alarm Status LED will flash green to indicate that data is being collected The data collection process will last as long as you allow up to a maximum of two hours In general a longer collection period will provide a closer representation of normal plant activity Typically 15 minutes will be sufficient to provide a good representation NOTE If the DD1000 is to be referenced against an iso kinetic sample the collection period will be the length of the sample run Step 3 The purpose of this step is to use the DD1000 control potentiometers to determine the dust level from the information stored during the collection period of step 2 Slowly rotate the multiplier potentiometer the one labeled X1 X10 X100 X1000 counter clockwise At some point the Alarm Status LED will change from flashing green to flashing red At this point slowly rotate the multiplier potentiometer back clockwise to the nearest scale marker The Alarm Status LED should return to flashing green Now slowly rotate the units potentiometer the one labeled 0 to 10 counter clockwise until the Alarm Status LED changes from flashing green to flashing red Now move the MODE switch back to the ALM position It is now possible to read the dust level The dust level is found by reading
8. ree duct diameters downstream and upstream In many applications a compromise must be made and the sensor would be fitted in a position which satisfies the majority of the above requirements The DD1000 must be mounted to metal ductwork in order to be electrically shielded from interference signals The DD1000 should not be mounted in direct sunlight or in areas where the ambient temperature may exceed 40 to 160 F If you require further advice on any installation aspects please consult BinMaster The DD1000 comes with both 1 14 NPT or 3 2 NPT male threads for mounting purposes A sanitary fitting is also available which can provide for quick disconnect and removal WIRING OF POWER AND RELAY CIRCUITS The DD1000 is powered from 115 VAC 50 60 Hz at 3VA The ungrounded line conductor is connected to terminal L1 of CON4 and the neutral conductor is connected to terminal N ot CONN4 The equipment grounding conductor must be connected to the green ground screw provided in the enclosure Wiring to the unit should comply with the National Electrical Code and local codes Two SPDT relays are provided for operations of auxillary alarms and controls at user discretion Alarm 1 relay is the Early Warning ouput and Alarm 2 relay is the failure alarm output The relay contacts are rated for 10A at 250 VAC or 30 VDC Figure 1 ALW SET IWS AYG MODE RESPOWSE ALARM d ALARMS HC C HO HO HO HEUTRAL LIHE EARLY WARNING ALARM SET
9. the scale position of the units potentiometer and multiplying it by the scale position of the multiplier potentiometer This dust level corresponds to the normal operation of the plant and may be referenced to an iso kinetic test if required NOTE If it is not possible to make the LED change to flashing green the sensitivity will need to be reduced by moving the jumper on CON2a to connect both pins together Step 4The purpose of this step is to set the alarm levels based upon the dust level found in step 3 First it will be necessary to decide the level at which the High alarm relay 2 is to be triggered This will depend upon the type of plant and the local authority recommendations When a High alarm level has been decided upon the DD1000 may be programmed to this value by adjusting the settings of the units and the multiplier potentiometers Divide the desired alarm level value by 1 10 100 or 1000 to give a number between 0 and 10 Rotate the unit s potentiometer to this new value Rotate the multiplier potentiometer to the number you divided by to get the setting for the unit s potentiometer i e 1 10 100 or 1000 For example if the desired alarm level is 1500 units you would divide this value by 1000 to give 1 5 The unit s potentiometer would then be set to 1 5 and the multiplier potentiometer would be set to x1000 The Early Warning alarm alarm 1 will be triggered at HALF of the value set for alarm 2 In the above exampl
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