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LSS2004 Continuous Dust Concentration Monitor

User Manual

Anronx Technology (Beijing) Co., Ltd.

1
 Contents
OVERVIEW .................................................................................................................................... 3
1.1 Applications........................................................................................................................ 3
1.2 Principle ....................................................................................................................... 3
INSTALLATION ............................................................................................................................ 5
2.1 Prepare for Installation .................................................................................................... 5
2.1.1 Choose the position ................................................................................................ 5
2.1.2 Determine the Length of the Optical Path ........................................................... 5
2.1.3 Prepare for the Flange ........................................................................................... 5
2.1.4 Prepare for Data Cables ........................................................................................ 6
2.1.5 Prepare for Purging System .................................................................................. 6
2.2 Installation ......................................................................................................................... 8
2.2.1 Mechanical Installation.......................................................................................... 8
2.2.2 Electricity Connection............................................................................................ 9
SET MEASURE RANGE ............................................................................................................. 12
ONSITE CALIBRATION ............................................................................................................ 13
CALIBRATION ............................................................................................................................ 14
MAINTANANCE .......................................................................................................................... 16
6.1 Optics ............................................................................................................................... 16
6.2 Purging System ................................................................................................................ 16
TROUBLESHOOTING ............................................................................................................... 17

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 1
OVERVIEW

1.1 Applications

LSS2004 Dust Concentration Monitor is a new generation product, which can work continuously
for a long time in very harsh circumstances, such as in the wind, the rain, the thunder and lightning,
the dust, the high temperature and so on. At present it has already been widely applied in the
following fields: the particles density test in the fixed source of pollution haze emissions
continuous monitoring system (CEMS), the monitoring of filtering equipment efficiency, the
monitoring to the combustion efficiency, the measuring to the dust concentration in the industry
process of manufacturing, the monitoring to the dust in the Industrial and mining enterprise for
health protection, the workshop, the dust load monitoring in the plant, the scientific research, the
test in the field, etc., involving the industries including the cement, the thermal power, the iron and
steel, the metallurgy, the refinery, the aluminum, the petrochemical, the papermaking, the glass
industry, and so on.

1.2 Principle

LSS2004 is a laser-based backscatter particulate monitor that is designed to measure dust loading
of combustion exhaust gas stream. The electrical output from the LSS2004 is proportional to the
light scatted back from the particles in the gas stream .The high stable laser signal source projected
into the gas flue and those particles can reflect the light whose intensity is proportional to the dust
content of the gas stream. The LSS2004 receives the weak laser signal which is reflected by
particles, then calculates the concentration of dust by specific algorithm.

The instrument is composed by three major parts: the electronic system, the optical system and the
mechanical part. The electronic and optical components are protected by mechanical elements.
The electronic system uses the digital signal processing technology, which is divided into four
parts, including the laser emission module, the optical receiver module, the central process module
and the interface module. It uses the advanced digital signal processing techniques and the
corresponding embedded software to control system, to realize the functions like the Adaptive
Control of light Power, high dynamic range self-adaption lock phase amplification technology, the
extremely low zero drifting designing, anti-adverse circumstance, provides fast, reliable and
accurate data of the dust discharge.

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1.3 Specifications (Standard System)

Principle Optical backscatter of light from a red Laser

Measuring object Particles in the gas steam

Material : Mental
Optical head Dimensions : 185×160×160 mm (L×W×H)
Physical Flange : inner dia. Ø 65mm
Characteristics Purge blower pipe : Ø40mm
Physical Weights : 2 Kg
Degree of Protection : IP66
Optical
Laser Diode, (650 ±20)nm, 10mW
Characteristics
Range : (0～100, 500, 1000, 2000, 10000)mg/m3, Selectable
Zero Drift : ±2%FS/24hr
Measuring Span Drift : ±2%FS/24hr
Characteristics Repeatability : ±2%FS
Response Time : ≤ 10S
Measuring Length :（0.5～20）M
Power Requirements DC 9～24V/0.3A

Ambient Condition -20ºC～+50ºC

Analog output : (4～20)mA
Output
Digital output : RS485

The LSS2004 is designed to meet or exceed all requirements of the HJ/T 76-2007 Specifications
and test Procedure for continuous Emission Monitoring systems of Flue gas Emitted from
Stationary Sources.

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 2
INSTALLATION

2.1 Prepare for Installation

2.1.1 Choose the position

Choosing the correct position for installation which can make sure the LSS2004 run reliably and
effectively. Please refer to the standard HJ/T 76-2007, please pay more attention to the following
points:

1. The conditions such as: the vibration, temperature, the stability of air stream, the distance
of the air upstream and downstream bent pipe or reducer.

2. The corrosive and noxious gas may damage the electronic components (for example the IC
plug, connectors) easily, reduce the life of product and prevent the operator to maintain.

3. The installation position should be easy to arrive. There must be full access of installation
and maintenance.

4. The assignment of signal wire (distance, route and the mutual interference with other
electromagnetic equipment).

5. In order to resist thunder, lightning and surge the safe protected earth resistance should be
less than 10ohm.

2.1.2 Determine the Length of the Optical Path

After choosing the correct installation position, measure the diameter of flue, and then work out
the length of optical path of instrument. If change the position of installation the diameter of flue
changes, so that the optical path length should be reset.

2.1.3 Prepare for the Flange

Open a hole at the stack or duck, and prior fixed the intermediate flange (buries or welding in
advance), its inner diameter must be bigger than 70mm. The provided transition flange whose
bolt holes distance is 130mm and external diameter is 70mm. Shown as following Figure 1.

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 Figure 1 Dimension of LSS2004 Flange

Note:

1) When welding flange please pay attention to the direction of the bolt hole, shown in above
figure 1, it is in order to be convenient for mounting weather cover.

2) When welding flange it should be perpendicular to the flue (as below Figure a) or slightly
downward sloping (as below Figure b), but can’t be upward sloping (as below Figure c). It can
avoid the water vapor stream to aggregate in the lens of window when the humidity of dust
combustion exhaust gas stream is high

a) Be perpendicular to flue b) Downward sloping c) Upward sloping (wrong!)

2.1.4 Prepare for Data Cables

Prepare for the data Cables from the control room to installation places (multi-core cable, with
outside belt covering, the diameter of cable is 0.35~0.5mm).

The connecting details of data Cables and I/O ports of LSS2004 refer to section 2.2.

2.1.5 Prepare for Purging System

Prepare for the protecting air which is used to avoid optical window lens to be polluted.

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Mechanical Description:

the purging system consists of the following major components:

1. The air tap of the instrument is the connector which connects with the purging system, whose
external diameter is 40mm with 1 inch pipe thread.

Figure 2 LSS2004 Air Tap

2. The air blower: it’s optional equipment.The pressure from air blower should be 200Pa more
than that of measuring point.

3. Weather cover: When the air blower installs outdoor, a weather cover must be given.

4. Blower intake air filter and associated pipes and hardware

Electrical Descriptions

Usually the air blower should be provided a 220V AC power supply, so the power supply should be
preserved in the installing flat.

Operation Tips:

1. The entry of air blower must fix a filter, and maintained in good working conditions in order to
guarantee the air clean.

2. The exit of air blower is connected to the air tap of LSS2004 by hose whose internal diameter is
40mm. Make sure it is always tied tightly.

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3. Interruption of the protective Purging System requires immediate corrective action by the user.
In no case the instrument can be placed in service or mounted on the stack without the Purging
System in operation.

Instrument Air Purge Option

If use a compressed air supply instead of the air blower, should prepare a connector. (1 inch to
8mm) Just As follows:

2.1.6 Other Spare parts and Tools

If use the UserMonitor control software manufacturer supplied, should have RS485 port on PC, or
provides RS485-232 connectors. Prepare for internal hexagon wrench, scissors and multimeter.

2.2 Installation

2.2.1 Mechanical Installation

Steps:

1. Fix LSS2004 to the welded flange in the stack.

Figure 3 Installation

Pay attention to the requirement of direction and angle which refer to section 2.1.3. If the
installation of welded flange is wrong it should be amended.

2. Put the controlling cable through the connector cover. (Showed figure 4 as follows)

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 ① Connect with the plug of LSS2004;

② Insert it into the socket.

Figure 4 the connector of LSS2004

3. Make sure the power is off, and check the mark of the controlling cable, which should be
connected to the corresponding wire of connector of LSS2004. Finally fix the connector cover to
the instrument.

4. Install the weather cover: 3 screws should be used to fix the weather cover and
intermediate flange.

5. Install purging system.

Note:

When installing outdoor, please make sure the Weather Cover fixed

2.2.2 Electricity Connection

1. Power supply: 9~24V DC.

Note: LSS2004 and the current loop should be provided power supply separately.

2. Ports: LSS2004 has a connector, including (4~20) mA current loop, the RS485 output port
(optional). The definitions of each connector are illuminated in figure 5 as follows:

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 Figure 5 The ports’ definitions of controlling Signal of LSS2004

(4~20) mA Current Loop ports

LSS2004 provides a current loop analog output, 4mA corresponds zero, and 20mA
corresponds full range.

No. 4 point connects to the connector Loop (+).

No. 5 point connects to the connector Loop (-).
No. 6 point connects to the shielding line.

The formula of Current I and Concentration Value of dust D (mg/m3) is:

D = Span ÷16 × ( I－4 )

The external DC power supply Vcc and the load resistance RL need to satisfy some requirement as
below:

2 ≤ [(Vcc－5) － I× (40＋RL)] ≤ 50;

I×(Vcc－5) － I2×(40＋RL) ≤ 0.3;

The units of those parameter: Vcc: Volt; I: Ampere; RL: Ohm.

For example: Vcc = 24V, RL =250Ω

The connection can choose in-isolated (3-wired, needs 1×24VDC power supply) or isolated (4-
wired, needs 2 ×24VDC power supply). The wiring schematic drawing sketch is illustrated in
figure 6.

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 Figure 6 (4~20) mA Current Loop Connection

a) 3-wired connection mode: connect the V+ point of terminal blocks to the anode of
24VDC power supply and GND point to the cathode separately by a 2-core cable for supplying the
power. Connecting LP+ point of terminal blocks and V+ point with a short wire, and connect the
and the cathode of 24VDC power supply, and between LP- point and 24VDC connect an Ammeter
or a load resistance(250Ω), then can obtain (4~20) mA or (1~5)V signal.

b) 4-wired mode: connect the V+ point of terminal blocks to the anode of 24VDC power
supply and GND point to the cathode separately by a 2-core cable for supplying the power.
Connecting LP+ point of terminal blocks to the anode of -24VD power supply and LP- point to the
cathode separately, and between LP- point and 24VDC connect an Ammeter or a load
resistance(250Ω), then can obtain (4~20) mA or (1~5)V signal.

RS-485 I/O port

The connector level conforms to the TIA/EIA-485-A standard, the ports are:

No. 10 point of port connects to RS-485 D (+).

No. 11 point of port connects to RS-485 D (-).
No. 12 point of port connects to Shielding line
Check whether the connection is correct, especially the point of 485 D (+) and 485 D (-),
simultaneously check the Shielding line is all right.

Using the controlling software named UserMonitor can check and record the value of dust density
by connecting RS-485 port, and setup the range and the value of calibration. The method of
operation is illustrated in appendix 1: UserMonitor software manual. Please contact our technology
engineer.

If you want to communicate with CEMS by RS485 port, please contact with our engineer to fetch
some information of transport.

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 3
SET MEASURE RANGE

Usually set the range to be 1—2 times higher than the maximal concentration of the emission
source. Its range has been set prior transportation by information provided by customer. Because
the backscatter signal of particles is related to physical and optical characteristics. When there is
the same concentration at the different emission source place the signal may be different, so the
range that has been set may not suit to all kinds of situation. If the output signal is too low it may
not sensitive enough, but if the output signal is too high it may be out of the range.

If the reading value is greater than that of full scale, should expand the range before the referential
experiment. Can modify it by UserMonitor software, or decrease the signal gain value, to make the
reading value is above 30% of the full range.

After adjustment, must record the new span reference value by the calibrator, which is the basis for
maintenance in future.

Note: Power off when open the back cover. Contact with technical support （010-
51652775）before adjust the signal gain value

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 4
ONSITE CALIBRATION

After the instrument installed and the appropriate measuring range set, it cannot make sure the
output value (X) is equal to the real value (Y), so it needs a formula Y= KX + B, to adjust the
output value to make it close to the real value. It called onsite calibration.

The proper values of K and B which have been worked out by reference experiment should be
recorded into the parameter setting of the CEMS system.

Note:
The instrument as part of the CEMS must be calibrated onsite right after installation,
otherwise may not pass the acceptance inspection of the EPA.

The differences between calibration and onsite calibration:

Calibration can be used to check the consistency after working for a period of time by calibration
kits provided, and the onsite calibration mean to establish correspondence between the measure
value and real value

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 5
CALIBRATION

The system is equipped with a calibration kit by which calibrates Zero and Span. Each calibration
kit is unique to the monitor for which it was adjusted. It is labeled with the same serial number that
matches the monitor for which it was adjusted.
1 Positioning Pin

2 Light-in Channel

3 Light Reflect Channel

4 Adjust Screw

5 Zero

When calibrating, open the hinged section which cover the calibrated orifice (ref. the below photo
1) in the monitor, and aim the Positioning pin of the calibration kit at the 2 pinhole (ref. the below
photo 2) beside the calibrated orifice, then record output value. The calibration kit can be rotate
180 degree to calibrate Zero and Span. Please record the output as a reference value for the first
time usage.
1 Calibrated Orifice

2 Pinhole

When doing zero calibration the output value must be zero (less than 2% of the full scale regards
as zero), if not, should open the cover to adjust zero potentiometer. When doing span calibration
the output value (usually set to 60 percent greater than the instrument full scale) should not exceed
the ±2% of the original value recorded before, or else the signal gain should be adjusted.

Note:

1. Before doing calibration please make sure the external window glass of both
calibration kit and the instrument is clean.

2. Please TURN OFF the power when opening the monitor’s cover. Propose to contact
technical staff before adjusting the potentiometer 010-51652775

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Suggest that the instrument must be calibrated after maintenance or adjustment, and record the
output value as the basis for maintenance in the future.

The calibration kit is also optics, so please put it into box and properly store in clean environment
to avoid polluting or missing.

The instrument has automatic zero calibration function which works automatically every 24 hours.

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 6
MAINTANANCE

6.1 Optics

LSS2004 is designed for long-term continuous running. Only the external optical windows and
surfaces may be polluted gradually, so it needs to clean regularly.

Cleaning Materials: may use soft cloth or cotton swab with 50% of the alcohol and distilled
water solution, and pay much attention to use Non-oily alcohol. Or can use optical lens cleaning
cloth. When the surface of the optical window is polluted by dust it must be cleaned, or it will
reduce the accuracy of result.

Cleaning Procedure: Three days after installation, please check the external optical window for
the first time to make sure it’s clean, and 30days later check once more. If there is no much
pollution you can check it every 3 months.

If you find the working condition is bad by the first inspection, the optical window is polluted
seriously, so should check whether the purge equipment work properly. In that case it may needs to
change air filter regularly, and increase the frequency of routine inspections.

Two surfaces must be cleaned before calibration: the external window of monitor and calibration
kit.

Note: All internal optics has been adjusted in the factory, so please don’t adjust
by yourself.

6.2 Purging System

The purging system is the support equipment. In the positive pressure flue, must provide the purge
equipment such as air blower, and keep working 24 hours a day, in order to slow down the
polluted speed of the optics. The purge system should be maintained regularly to check the
working status of air filter. In order to ensure enough clean air you may need to clean or replace
the air filter regularly. The method is: after removing the air filter you should purge or wash it. If
surface of the filter is not damaged and drag coefficient is not big, it can be reused yet.

Furthermore, pay attention to the location of filter, and make sure something like rain is prevented
from entering the filter and the instrument.

Make sure to keep the purge system working 24 hours a day!

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 7
TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Power supply: The instrument and the current

loop are provided power separately
No output in the
1 The Line: the communication between the
Current Loop
instrument and DCS is blocked or Check whether the
interfered. power is normal

No communication in
2 Power supply failure or damaged
digital ports

3 output too low Optics contaminated

Clean the optical

4 output unstable Optics contaminated window.

output keep zero

5 Laser transmitter damaged Contact us

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