Dust Monitoring Device

User Manual
V1.1

Please read this manual carefully before operation

 Content
1 Introduction ............................................................................................................ 1
1.1 Overview .......................................................................................................... 1
1.2 Application Scope ............................................................................................ 1
2 Principle, Characteristics and Technical Specifications ........................................ 2
2.1 Measuring Principle ......................................................................................... 2
2.2 Technical Features ............................................................................................ 2
2.3 Technical parameters ........................................................................................ 3
3 Dust Monitor Installation and Connection ............................................................. 4
3.1 Preparations ...................................................................................................... 4
3.2 Equipment installation ...................................................................................... 4
3.3 System calibration ............................................................................................ 8
3.4 Dynamic range setting of system ..................................................................... 9
4 Range Adjustment ................................................................................................ 11
4.1 The concept of range ...................................................................................... 11
4.2 Measuring range adjustment .......................................................................... 11
5 System fault diagnosis and maintenance ............................................................. 13
5.1 Maintenance ................................................................................................... 13
5.2 Trouble Shooting ............................................................................................ 13
5.2.1 First-type failures ............................................................................. 13
5.2.2 Second-type failures......................................................................... 14
5.2.3 Third-type failures ........................................................................... 14
6 Installation instruction ......................................................................................... 16
7 Commissioning .................................................................................................... 17
7.1 The interface shows 0 MG/M3 ....................................................................... 17
7.2 The interface shows 999.9 MG/M3 or out of range. ...................................... 18
8 Warranty Policy.................................................................................................... 20
1 Introduction

1.1 Overview

Welcome to choose Dust Monitoring Device. This user manual describes the
installation, operation, inspection and maintenance of device. It is deigned based on
the backscattering principle of the dust particles for the on-line continuous
measurement of particulate pollutants from stationary pollution source.
Caution:
 Uses a 5mw, 650nm semiconductor laser, whose laser beam and the reflected
light directly into the eye will cause serious damage.
 Do not carry out power-on operation before installing on the stack/ flue.
 Do not enter the stack/flue while the device is running. Staring at the laser beam
 and its reflected light shall be prohibited.

1.2 Application Scope

Device can be used in the real time continuous measurement of the particulate
pollutant concentrations for various emission sources. It can be facilitated with flue
gas monitoring system, used separately or connected into a dust monitoring network
with several such device sharing a front platform. The device is applicable for dust
monitoring of power plants, steel mills, cement plants, etc., and for the process control
of dust collecting equipment and other powder engineering.

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2 Principle, Characteristics and Technical Specifications

2.1 Measuring Principle

The system principle is shown in Figure 2.1.

L
D

RT
PD1

PD0
SHEILD

Preceding
Dirver Pretreatment

Modulation Demodulation

Opto-coupler
CPU
isolation

4-20mA
HMI display module
output

Figure 2.1 System Principle

The optical parts include laser source, power control, photoelectric sensor and
scattered light receiving. The 650nm laser beam sent by the laser at a tiny angle into
the emission source, where it acts with the dust particles to produce scattered light.
The backscattered light will be processed in the sensor into electrical signals. The
circuit part will realize the photoelectric conversion, laser beam modulation, signal
amplification, demodulation, light source power control, V/ I conversion and HMI
display. Calibrator is used to generate stable optical signals to zeroing and span
calibration of the device.

2.2 Technical Features

 Laser backward scattering principle can prevent the laser beam from swinging
when the refractive index is uneven during the mechanical vibration at uneven
temperature.
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 Single-side installation without optical path alignment.

 The on-site display can read the dust concentration in the field.
 After the laser beam is modulated, the system can significantly improve its
anti-interference ability.
 The device design has been implementing the thinking of "no tool" on-site
installation, to minimize the complexity of field installation.
 (4-20) mA standard industrial current output makes the connection easy.
 Device overall power consumption is very low at around 3w.
 Generally, the standard setup parameters are applicable to the flue wall with a
thickness less than 400mm and a diameter greater than the device stack label size.
The measuring area can be customized as required specifically. Users may also
adjust the area under the approval and guidance of the maintenance personnel.
Note: has adopted a 128x64 graphic LCD for display. The LCD contrast display
adjustment can be made through adjusting a potentiometer on the front panel.

2.3 Technical parameters

Size\Weight 158mm×158mm×273mm\3kg

Temperature: -40℃~65℃
Environment requirements
Relative humidity: 0-100% RH
Measuring error ±10%

Temperature Max300 ℃ (Higher temperature

Medium condition
requests to be customized)
Display mode 128x64 Graphic type LCD
Signal output (4-20)mA,MAX485

Maximum output load 500Ω

Sensitivity 2mg/m3
Measuring range 0-500mg/m3,0-10g/m3 (can be customized)
Measurable stack size 1m-15m
Power consumption 3W
Power supply DC 24V±10%

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 User Manual of Dust Monitoring Device

3 Dust Monitor Installation and Connection

3.1 Preparations

The appropriate installation is very important for its effective operation.

Consultation of relative environment protection laws and regulations shall be make to
elect a proper installation point before the installation, relative maintenance personnel
shall also be consulted. The key factors which shall be considered are:
1. The installation position of the optical head, for which vibration, surrounding
temperature, flow stability, the distance between the elbows or variable diameter at
the downstream and upstream of the flow, as well as the safety of the installation and
maintenance channels shall all be considered.
2. Power supply, cables, pipeline and overload protection.
3. Arrangement of the signal lines (distance, paths and interference with the other
magnetic equipment).
4. People are prohibited to enter the flue/stack as they are easy to be hurt by the
laser.

3.2 Equipment installation

 Flange embedding and welding

The embedding or welding strength of the flange shall be able to endure the weight of
the dust monitor body, which is about 15kg. Pay attention to the location of the flange
during the welding (Figure 3.1).

Figure 3.1 Directions of the flange welding

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 Protective gas connection

After welding the flange to the stack, if the pressure within the stack is negative,
shielding gas source will be needed. When under negative pressure, an air filter can be
connected directly at the intake of the gas chamber. When under positive pressure, a
fan or compressed air source is necessary to guarantee the air is fresh.
When the measuring point is negative pressure, the air filter can be installed on the
meter body of the dust monitor. If the measuring point is positive pressure, a high
pressure fan will shall be connected in series between the dust monitor and the filter.
(device body has inch thread G1" connector for backblowing), fan is suggestted
choosing power supply of 220V / 50Hz, power 370 w, maximum wind pressure 12
kPa, biggest blowing rate 60 m3/h of fan.

Figure 3.2 Negative pressure

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Figure 3.3 Positive pressure

 Electrical connections
After the system has been installed, the cables can be connected. The device is
configured with a junction box for the connection. The positive and negative
terminals are shown in Figure 3.3. There are totally 4 terminals with the following
definitions:
1---24VDAC positive pole of the power supply
2---4-20mA positive pole of the current output
3---Public terminal (24VDACnegative pole of the power supply and 4-20mA negative
pole of the current output)
4--- MAX485A
5--- MAX485B

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5 2

4
3

Figure 3.4 Aviation joint electrical connection

1：+24V power supply；2：4-20mA signal output；3：GND；4：MAX485A；
5：MAX485B
Communication protocol:
Dust monitoring device control order (RS485)
1. Data interface standard:
Dust monitoring device supplies an isolated RS-485 serial interface for user, user
can transmit control order and receive data through this interface, and the definition of
serial interface exchange format is shown as bellow:
Baud rate: 115200
Data bits: 8
Stop bit: 1
Parity bit: NULL
2. The order sent to dust monitoring device
The order sent to dust monitoring device is 8 bytes, sand sequence and meaning
are shown as bellow:
The first byte: device address.
The second byte: function code.
The third and forth byte: initial address.
The fifth and sixth byte: read quantity.
The seventh and eighth byte: CRC Check, the summation of the previous 8 bytes,
lower byte ahead.
3. The response of dust monitoring device
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 User Manual of Dust Monitoring Device

The order by dust monitoring device response is consist of multi-byte, send

sequence and meaning is shown as bellow:
The first byte: address.
The second byte: function code.
The third byte: return the number of bytes.
2* N byte in the middle: N is the number of register bytes, return the number of
bytes.
The last 2 byte: CRC Check, the summation of the previous 8 bytes, lower byte
ahead.
4. Illustration
PC send: 01 03 00 1C 00 02 CD 05
Dust monitoring device answer: 01 03 04 43 6E CC CD FF 1A
The red bold byte is effective dust data (the dust concentration is 238.8 mg/m3).

3.3 System calibration

Main interface display as follows:

Concentration

Concentration
Set optical path
Concentration

The concept of optical path: optical path = stack inner diameter+ wall thickness+
0.2m, the largest optical path is 2.5 m. Check if device optical path and site flue size
conform to requirements before installation, if not, please contact technical personnel
to solve.
The system is configured with a calibrator test performance of device, not to calibrate
zero point and full span calibration. This device enters the "Z value" and "Full value"
in the calibration interface in cooperation with the remote control in automatic
confirm the enter key for automatic calibration. Don't need to disassemble the rain
cover to accurate calibration fast. There is no effect on online measurement of the

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device.
Use the remote control to carry out the system calibration by completing the
following steps:

 Under the main interface, press “ ” key on the remote control to enter the

maintenance interface;

 Under the maintenance interface, use the “ ”and“ ” keys to select the

“Calibration” menu;

 Press “ ” key to enter the password. Then press “ ”and“ ” each for twice in

turn;
 Enter the calibration interface, you may select "Z value" and "Full value" and set

the contrast menu by pressing “ ”and“ ”. Press “ ” key to confirm the

zeroing and span calibration. Fine-tune zero point and full scale point with the
guidance of professional and technical personnel .

 Press “ ” key to enter the main interface and wait for the reading to be stable.

Main Main CAL

Zero Span Z
View Set Calib. View Set Calib.
Full value K

Fig. 3.5 maintenance interface Fig. 3.6 Full value Fig. 3.7 Adjust comparison coef.

3.4 Dynamic range setting of system

Before shipment, dust monitor has been adjusted in the dynamic range basing on
the users’ feedback. However, owing to the relationship between the light scattering
and the optical characteristics of the dust, its concentration corresponds to the same
signal output for a specific emission source, but different emission sources with the
same emission concentration may have different output signal. This may result in the
factory setup differing from the site conditions of the users. Too low output signals
lose the sensitivity of device, too high output signals exceed the dynamic range after
installation.
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 User Manual of Dust Monitoring Device

If installed at the back of the emission source, with the reading has been 5% lower
than the measuring range, please increase the signal gains before reference testing; if
installed at the back of the emission source with the reading exceeding the full span,
please decrease the signal gains before reference testing.
Use the remote control to adjust the signal gains by completing the following steps:

 On the main interface, press “ ” to enter the maintenance interface;

 From the maintenance interface, select “Set ”menu; press “ ” to enter the

password, and press “ ” and “ ” twice for each in turn;

 After entering the “Set” interface, please select “Gain” and press “ ”to

confirm;

 Press “ ”and“ ” to select the gains, and press “ ” to confirm.

Note:
Unless the dust concentration is especially low, do not select “X8” as the gain level.
The factory default gains of the dust monitor is “X2”, which does not need to be
adjusted if not necessary.

Set Set
Gain Range Mean Gain
x1 x2 x4 x8
R
Enter

Fig. 3.8 Select and setup the gain Fig. 3.9 Select the gain

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4 Range Adjustment

4.1 The concept of range

The general device has terms such as zero point, range and linearity.
Some concepts of backward scattering method is quite different with general.
First, scattered light created by the laser beam project on the particles is directly in
proportion to the scattering area of the particles (this is the single-scattering case), and
the scattering area of the particle mass under a specific range of particle size is in
directly portion to the concentration of the particle mass.
The zero point in the scattering method indicates there is no scattered light. The
linearity of the scattering refers to the linear relation between the output current and
the scattering intensity, rather than with a linear relationship with the particulate
concentration. Because the later is related with the emitting source and the regression
model, while the former is actually disclosing the actual optical/electrical
characteristics of the device.
On the basis of the above, the factory ranges is not accurate. An accurate one should
be determined through reference. Please refer to the corresponding sections for the
setup of reference and range.
The site calibration (weighing comparison). Install device in the flue, and set the
appropriate range, but cannot ensure the output value (X) is equal to the real value(Y).
While need calibrate through the reference experiment, namely weighing comparison,
to determine B and K values of the equation Y = KX + B to adjust the output value,
make it close to the true output values. General comparison duration is once for a
quarter. Shorten the cycle according to actual situation.

4.2 Measuring range adjustment

Use the remote control to adjust the measuring range:

 On the main interface, press “ ” to enter the maintenance interface;

 Select “Set” from the maintenance interface, and press “ ” key to enter the

password (the same with the above);

 Enter the set screen, then press “ ”and“ ” to select measuring range.

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 User Manual of Dust Monitoring Device

Set Set
Gain Range Mean Range 0-500mg/m3
R Enter

Fig. 4.1 Select range menu Fig. 4.2 Setting range

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5 System fault diagnosis and maintenance

5.1 Maintenance

 Initial maintenance after installation

The user is recommended to examine the device three days after the installation for
the first time, and examine the second time after 30 days. If there is no problem after
above two examinations, device can be examined at an interval of 3months. The chief
checking items are whether the optical window has been polluted and the cleaning
system remains effective.
 Normal maintenance
Under normal circumstances, it is recommended to examine once per quarter. If the
device is found under poor circumstance during the first examine, which can not
satisfy the requirements, user needs to replace the air filter frequently. The regular
maintenance cycle shall also be changed basing on the actual conditions.
All the internal optical components were adjusted and installed with special tools
before shipment. Users shall not make adjustment.
 Air filter
There is an air filter in the cleaning system to protect the optical head from dust. The
air filter shall be cleaned and replaces regularly. It may be removed and blown with
air or washed with clean water. If the filtering surface is not damaged and the air
resistance is not too large, the filter may continue to be used. Please check the
operation of the filter frequently to ensure enough cleaning air. By the way, pay
attention to cleaning the area for placing the filter to prevent rain, etc. from touching
the fan and device through the filter.

5.2 Trouble Shooting

5.2.1 First-type failures

Essence of the failure: The device might have been damaged. Handling method:
Return it to the factory for repairing.
Instructions for failure diagnosis:
(1) The laser does not illuminate;

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(2) The output remains the same when the calibration module is used to calibrate the
zero point and range; the device output remains the same with or without a piece of
white paper placed 500mm in front of the device;
(3) The 4-20ma output remains the same.

5.2.2 Second-type failures

Essence of the failure: The device setting is incorrect. Handling method: Consult with
the factory and handle the problem on site.
Instructions for failure diagnosis:
(1) The displayed concentration is 999.9 mg/m3;
(2) The range is exceeded;
(3) The displayed concentration is 0 or very low;
(4) There is no flue gas coming out of the flue but the device output indicates high
dust concentration; but the zero point is accurate when a calibration module is used
for calibration;
(5) The laser does not illuminate.
Instructions for failure handling:
(1) The device optical path does not match the field conditions on site;
(2) The device optical path does not match the field conditions or the actual smoke
dust concentration is very high;
(3) The laser is zeroing calibrated or gain altered (increased);
(4) The device optical path does not match the field conditions on site;
(5) The laser is switched off in the device self-inspecting menu.

5.2.3 Third-type failures

Essence of failure: Incorrect installation and wiring. Handling method: Consult with
the factory
Instructions for failure diagnosis:
(1) The device does not work well due to incorrect wiring;
(2) Dust easily accumulates on the lens.
Instructions for failure handling:

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(1) Wire the device as indicated in the manual,

(2) If the pressure in the stack is negative, the device should be equipped with an air
filter; if the pressure is positive, then the device should be equipped with a fan. A fan
must be provided if the pressure is sometimes positive and sometimes negative.

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6 Installation instruction

(1) The standard dust detector accessories are configured for onsite working condition
with negative pressure. If the on-site working condition is positive pressure, then the
dust analyzer needs an air blower to purge. The wind pressure of air pleasure should
be slightly bigger than the pressure in the stack. Otherwise, after running a while, it
will pollute the lens which is inside of the equipment base and influence the measure
accuracy. If sometimes is positive pressure and sometimes is negative pressure, it also
strongly recommends to install an air blower to purge, which could reduce the
maintenance work of optical path.
(2) The location of installation point should select a place with uniform dust
concentration, steady flow rate and not at corner as well. The instrument should install
vertically to the flue pipe and stack wall.
(3) The instrument wiring instruction: there is wiring connection identification
number on the power interface. 1 connects to +24V, 2 connect to 4-20mA signal line,
3 connect to GND, 4 connect to 485A, 5 connect to 485B.
(4) Asbestos gasket, used for buffer and thermal insulation, install between flange and
instrument. If the chimney temperature is above 300℃, it is needed to add more
quantity and more thick asbestos gasket for thermal insulation. The highest
temperature the instrument can burden 65℃.
(5) The function of measuring module: the measuring module, as spare parts for
maintenance, is used to calibrate 4-20mA and test the performance of instrument. If
the difference of LV value on two side of measuring module is larger than 100, it
prove the working operation is good.
(6) The function of remote controller: Easy maintenance and commissioning.
(7) The reserved sampling port should be convenient to see the laser beam from the
instrument to avoid the laser beam touch the flange and mounting wall.

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7 Commissioning

If newly installed dust analyzer shows 0 during furnace shutdown and displays data
when opening furnace, it is considered that this analyzer is in good working and no
need of any commissioning operation.
If the instrument occurs below problems when opening furnace, please kindly check
the below suggestion.

7.1 The interface shows 0 MG/M3

In general, LV value is quite low which is about 10. Below ways is sequenced but not
separate. If the first method is not workable and please try the second way as follow.
If the first method is workable, it is unnecessary to try the second method.
Method one: Zeroing by covered the laser device.
Unscrewed the black shell, the laser device can be seen in the middle. Then use the
barrier to cover the round hole front of the laser device. In this condition, Press “S” on
the remote control and then enter into calibration interface to zeroing. Once press
“OK”, the zeroing operation is completed. (This step does not need of calibration
module and span calibration.)
Method two: Increase the gain of software or electrical bit of hardware.
In the main interface of dust analyzer, press “S” on the remote control to enter into
maintenance interface, selecting into gain setting which can be used to increase the
gain.
There are 2 blue electrical bits under the second circuit board under the instrument
display. The left is gain electrical bit which shows “gain” on the silkiness and shift
again crosswise to increase the hardware gain.
Method three: increase the k value.
In the main interface of dust analyzer, press “S” on the remote control to enter into
maintenance interface, selecting into calibration option to set “K” valve. It can be
realized by adding K value.
Method four: By increasing optical path to expand the measuring range.
Under the LV value interface to adjust angle of the laser device, uses M4 hex wrench
to adjust two screws at backward of laser device. One screw is to adjust the angle of
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laser, and the other has fixation ability. The higher angle will increase the optical path
and LV value. Once the LV value reached 30-50, to tighten the screw which has flat
wisher, it is fine to fixed optical path at this point. In this condition, Press “S” on the
remote control and then enter into calibration interface to zeroing. Once press “OK”,
the zeroing operation is completed. (This step does not need of calibration module and
span calibration.)

The long screw (left) is used to adjust the angle of laser device, and short screw (right)
has the fixation ability.

7.2 The interface shows 999.9 MG/M3 or out of range.

If it is a new analyzer, please confirm whether the flange hole is missed or not, which
leads to the laser shot on the installation wall. The laser does not enter into flue pipe
so that it causes the full range.
If it is already installed for a period of time, the first task it to check the optical lens is
polluted and the flange end is blocked or not. At last please check that optical path
matches the chimney size. The optical length calculating method as follow: inner
diameter of flue pipe and plus thickness of wall. The largest optical path is 2,5 meter.
When there is large difference between theoretical optical path and instrument optical
path, it can be adjusted by following methods. Please noted that the operation should
be under guidance of technical engineer.
Method: Shorten the optical path and increase the optical path.
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Under the LV value interface to adjust angle of the laser device, uses M4 hex wrench
to adjust two screws at backward of laser device. One screw is to adjust the angle of
laser, and the other has fixation ability. The higher angle will increase the optical path
and LV value. Once the LV value reached 30-50, to tighten the screw which has flat
wisher, it is fine to fixed optical path at this point. In this condition, Press “S” on the
remote control and then enter into calibration interface to zeroing. Once press “OK”,
the zeroing operation is completed. (This step does not need of calibration module and
span calibration.)

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8 Warranty Policy

The device has been manufactured and designed based on the latest national standard,
and meets the requirements of ISO9001 quality management system.
The defective products must be returned to us, attached with a detailed problem
description. The company reserves the right to charge the field maintenance fees if no
failure and only improper use is discovered. The company assumes no responsibilities
for any loss or damage caused directly or indirectly by improper use or operation by
the buyer or any other party.
The manual relate only to device and components sold to the buyer, authorized
dealers, distributors and representatives. The warranty period specified in the manual
will not be extended due to any handling work during the service life.

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