LKS

Dust & Opacity Analyzer

Model: D10
Version: D10.0
Installation Instruction
(File: LKS Dust & Opacity Analyzer - D10.doc)
Dust & Opacity Analyzer D10

INSTALLATION MANUAL

1. SENDER & RECEIVER

 Location
Both of these units are rigidly mounted on opposite sides of the stack or duct so that
the sender light beam is at right angles to the flow of flue gases and gives unrestricted
illumination of the receiver solar cell. The following considerations should be taken
into account in choosing a suitable location.

 Temperature
The location of installation is preferable that units are installing where temperature is
at minimum. Conducted heat usually is not a problem and radiated heat, which has the
greater effect on the temperature of the units, must not exceed 1200ºC and where
difficulty is experienced in achieving this manufacturer should be consulted.

 Flue Gas Pressure

a. Positive pressure application

Mean, the pressure inside the chimney or duct is greater than atmospheric; the sender
and receiver units should be bolted to the mounting tubes using a gasket to provide an
airtight seal between the flanges. On oil-fired boilers a pressure wave may be caused
when the burner ignites, disturbing soot accumulations and depositing them on the
lenses of the units. Because of this, the units must be located as far as possible from
the actual flow gas outlet of the boiler. Injecting clean air to overcome the effect is
not usually practical as the momentary pressure can be severe. Accordingly it is
important to observe these precautions even when injected clean air is used during
normal running conditions. To prevent soothing-up of the lenses during normal
operations, air pressurised above the stack pressure should be fed via flexible tubing
into the 3/8” BSP tapping provided on each unit. The air supply should be switch on
before the boiler is fired and should not be switch off until after the firing equipment
has been shut down.

b. Negative pressure application

Mean, the pressure inside the chimney or duct is less than atmospheric; the sender and
receiver units should be bolted to the mounting tubes using washers to provide a 1/8”
(3mm) spacing between the flanges. Atmospheric air will be drawn through the gap
and into the units, so keeping the lenses free from soot. The ¼” BSP tapping should
be plugged.

2. STRATIFICATION

To ensure that the Opacity measured by the instrument is representative of that

emitted from the chimney, the influence of dampers, bends, tees, obstructions and
drought balance doors should be considered when selecting a suitable position.
Location of the units close to bends in the flue should also be avoided as momentum
of the flue gases may deposit dust on the lenses.

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

3. ACCESSIBILITY

 Sensor units must be located such that they are readily accessible for lens
cleaning, routine maintenance and servicing distance. Whilst the sensor units
will function correctly at temperatures up to 1200ºC positions of high ambient
temperature should be avoided as far as possible so that routine maintenance
and service can be carried out whilst the plant is in operation.

4. SCANNING DISTANCE

The length of light path in the flue gases affects the response of the instrument and in
general the obscuration for a given Opacity density will be higher for a greater
scanning distance. The scanning distance on recommended is kept within the limits of
0 feet to 3 meter. Where the distance between the duct walls is greater than 3 meter,
then the mounting tubes may be extended into the duct to reduce the scanning
distance.

5. GENERAL

Sensor units must be located away from the flame area and downstream of any flue
gas sampling or temperature tapping points, to avoided errors in these readings due to
infiltration of air.

6. MOUNTING

Recommended methods for mounting the units are given on drawing Pages No. 6 & 7.
Where a choice exists between mounting on a brick stack or steel duct, the former
location is preferable by virtue of the rigidity of the brick work and much-reduced
tendency to distort with changing temperature of the flue gases. In general,
temperature requirements are more easily met where the units are mounted on a brick
stack and there are fewer tendencies for soot to accumulate on the lenses.

It is essential that the mounting tubes are in correct alignment with one another and
this can be achieved by inserting through them a pipe of sufficiently reduced diameter
passing completely across the stack; the mounting tubes are then cemented or welded
into place. The guide pipe is removed prior to mounting the sensor units. An
alternative method is to install the mounting tubes as a complete length, the central
portion being cut away when the cement has set, or the welding has been completed.
In this method, the mounting plates will be fitted when the mounting tubes are in
position and care must be taken that each plate is accurately at right angles to its
associated tube.

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Dust & Opacity Analyzer D10

7. CONTROLLER

 Location
Controller should be located to suit site conditions, subject to the following
consideration: -

The maximum distance between the receiver and the controller will be governed by
the resistance of the cable used. A total resistance up to 200 ohms is acceptable,
corresponding to 1370 metres (1500 yards) maximum separation when wired with
3/.029” copper wire alternatively 228 metres (250 yards) maximum separation with
7/.0076” copper wire.

To assist in the dissipation of heat from the internal components, it is advisable to

select a location where the ambient temperature is at a minimum and in no case must
this exceed 70oC. The unit should be mounted away from excessive dust or grit and
must not be subjected to moisture or excessive vibration.

It is essential that the controller is located in a position where it shall be accessible

and safe for servicing.

 MOUNTING
The method of mounting the controller is illustrated on Pages 8 showing flush
mounting and surface (projection) mounting respectively.

The type number marked on the controller chassis indicates the supply voltage and
frequency required and the calibration of the meter for Full Scale Deflection.

 MAINS SUPPLY
Mains supply is fed to the controller which supplies stabilised voltage to the projector.
Standard equipment is available for operation over the ranges 230/260 volts or
100/120 volts at 50/60 Hz.

 ALARM CIRCUIT
Neon red and amber indicator lamps are incorporated in the controller. Two (2) Single
pole contacts 5A 24 VDC non-inductive load give facility for external alarm circuit.
Alarm also operates in the event of failure of the controller. The mute switch on the
controller may be used to isolate the external alarm circuit.

 ANCILLARY EQUIPMENT
Single Output of 4~20mA corresponding with 0-100% Opacity & Dust (scale), Full
Scale Deflection on meter, available for graphic recorder or remote meter.

An output of 4-20mA is available on the corresponding 0-100% Full Scale Deflection

equipment for Opacity and Dust.

In both cases the external load should have an impedance of less than 600 ohm

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

8. INTER-UNIT WIRING

The controller must be correctly earthed and wired in accordance with the diagram on
Page 14.

The supply to the external alarm circuit should be independently fused.

Note: The twin lead from the control box to the receiver must be in its own conduit
run or a screened twin cable used.

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

9. FLANGED AND MOUNTING

A + B = 101mm
Dimensions: “A & B” to suit ducting
Use the 3.1/8” thickness spacers draught stacks
spacers are not required when mounting on “A” “B”
forced draught stacks and should be discarded.
In this case an air tight joint is necessary. Stack or duct wall

Weld
Note
Arrow indicates direction
of gas flow in relation
to tube end cut-off

Lagging in locality of unit to

Outline of optical reduce radiated heat
it
2½” Bore pipe, welded into standard 4” Steel flange (B, S. 10 table ‘E’).
Mounting unit, including Flange drilled 5/8” with clearance 4 holes equiv.-spaced on a 5 ¾” P.C.D.
bolts and spacers

149
75
64

Fig. 1

ALL DIAMENSIONS IN MILLIMETERS UNLESS OTHERWISE SPECIFIED

Installation of Optical Unit Mounting Flange on Steel Stack or Duct
(Mounting Flange & Tubes Supplied by Others)

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Dust & Opacity Analyzer D10

Use the 3,0 (1/8”) thick spacers mounting on natural draught

stacks. Spacers are not required when mounting on forced draught
stacks and should be discarded in this case an air tight joint is
necessary

Outline of optical unit

3½” Bore pipe 2.75” O.D. Firmly cemented into

Mounting unit, including
stack wall and mounting plate bolted into position
nuts and spacers
using 3/8” dia. raw bolts or similar.

140
(5 ½”)

140
(5 ½”)

76(3”) 76(3”)

Fig. 2

ALL DIAMENSIONS IN MILLIMETERS UNLESS OTHERWISE SPECIFIED

Installation of Optical Unit Mounting Flange on Steel Stack or Duct
(Mounting Flange & Tubes Supplied by Others)

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 Dust & Opacity Analyzer D10

10. INSTALLATIONS
FIGURE 3
SURFACE (WALL) MOUNTING. DIMENSIONS IN MILLIMETRES.

100 195

20.0

265 225 165 165

20.0
155 80

90

FIGURE 4
FLUSH PANEL MOUNTING. DIMENSIONS IN MILLIMETRES

100 195

265
245 245 225

20.0

155
120

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Dust & Opacity Analyzer D10

11. TERMINAL DESCRIPTION

i) Power
N L(115V) L(230V) E

L(115)

L(230)
N

230VAC E
E
ii) Buzzer (24VDC)
Opacity or dust exceed the alarm value, the buzzer will give 24VDC

BUZZER
+ -

Note:
Be aware for the polarity for
buzzer connection, and do not use
the buzzer that exceed 80mA

Buzzer

iii) Sender & Receiver

SENDER RECEIVER
+ - + -
Note: Must beware of LED
polarity.

LED LDR

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Dust & Opacity Analyzer D10

iv) Contact 1 and Contact 2

When Opacity and dust is exceed the alarm value, C and NO will close.

Contact1 Contact2
NC C NO NC C NO

Buzzer

+ -
24VDC

v) Analogue Output 4-20mA (Dust and Opacity)

The maximum load is 400ohms and single output of 4~20mA corresponding with 0-
100% Opacity & Dust.
Opacity - 0%, Output = 4mA Opacity – 100%, Output = 20mA
DUST RANGE – 4000, Autosetup – 20%, Output = 7.2mA
DUST RANGE – 2000, Autosetup – 20%, Output = 5.6mA

OPACITY DUST
+ - + -

mA mA

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Dust & Opacity Analyzer D10

12. SETTING & CONFIGURATION

OPACITY: 100%
DUST: 4000mg/m3

Press SET Key

Press SET Key

DUST RANGE
>DUST RANGE
4000
SET AUTOSETUP

Press SET Key

Press SET Key Press UP/DOWN

AUTOSETUP Key AUTOSETUP
DUST RANGE
>SET AUTOSETUP 20% 19%

Press DOWN KEY

Press UP/DOWN
Press SET Key Key
>SET ISO-K SET ISO-K SET ISO-K
OPACITY CAL 800 0800

Press DOWN KEY

Press SET Key

SET ISO-K LED ON CALIBRATING…
>OPACITY CAL.

Press DOWN KEY

Press UP/DOWN
Press SET Key Key DUST UNIT
>SET DUST UNIT DUST UNIT mg/m3
mg/m3

Opacity Calibration :
i) Due to the different installation distance for sender and receiver.
ii) First do the Opacity calibration.
iii) Turn ON LED, press “SET key”, and select the “OPACITY CAL”.

DUST Calibration:
i. Holding down the “Mute Key” for 4 seconds, the meter will start to collect data and
accumulating the value. Dust calibration will done after 45 minutes.
ii. After done calibration, press “SET key”, select “SET ISO-K”
iii. Compare the ISO-K data and site data that you measure.
iv. Calculation:
DUST RANGE = ISO-K/AUTO SETUP. (Dust Range should not more than 4000, if more
than 4000 , it will automatically set to the default value 4000).

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

13. MAINTENANCE

 Sender and Receiver

It’s essential that the lenses be maintained in a clean condition. The frequency with
these should be cleaned depends upon the location of the units as described earlier,
and deposit occurs whilst the firing plant is in operation.

The inlet side of an induced draught fan is extremely satisfactory in that the intake of
clean air from atmosphere (filtered if necessary) will maintain the lenses in clean
condition during firing it may be found, however, that when combustion ceases and
dampers are closed to conserve heat, a built-up of pressure may occur which will
cause a deposit of soot on the lenses.

It may be necessary to clean the lenses after soot blowing or ash blowing. In all such
instances the need for cleaning will be evidenced by a rise in the instrument reading
other than would be encountered with normal combustion.

If this occurs, a routine procedure for cleaning the lenses at these times should be
adopted, and in any case the lenses should be cleaned at regular intervals of say once
per week to ensure that the dust & opacity reading are accurate.

After the lenses are cleaned, the sensor units must be securely closed or the balance of
airflow will be upset and atmospheric dust will be deposited on the lenses.

 Controller

It’s advisable to check the zero; full-scale deflection and alarm set point from time to
time to ensure the instrument is remaining accurate. The zero should, of course, only
be checked when the stack is clear and the lenses are perfectly clean.

If any change is found necessary, the setting up procedures detailed in the

commissioning instruction should be followed.

14. FAULTS

The equipment is designed so that wherever possible, components failure will cause
the alarm circuit to operate. Faulty operation is most probably caused by an
expendable component and if the fault is not clear by changing the LED lamp in the
sender and/or the relay in 10,000 hours. Short of physical damage, the life of the
Light Dependent Resistor.

In World there are the appointed agent that can only provided the service, such as
regular servicing of the equipment, which includes a comprehensive check of the
instrument using test reading to detect deterioration of components and thus reducing
the possibility of breakdown. Full detail will be supplied on the request.

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

15. TERM OF USED

Sender - The unit housing the LED.

Receiver - The unit housing the LDR

The sender and receiver are preferred to collectively as the optical units and will
normally be mounted on the chimney stack or flues leading to the stack.

Total light path - The distance between sensor units.

Scanning distance - The length of light path in flue gases.

The right is reserve to amend, without notice, details given in this publication.

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Dust & Opacity Analyzer D10

16. ELECTRICAL CONNECTION

3 7

8
Dust & Opacity Sender Receiver
4 Analyzer 9

10 + - + -
1 17 18 19 20

V0+ V0- V1+ V1-

E
Recorder or
External
Equipment

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Dust & Opacity Analyzer D10

17. OUTPUT CONNECTION

1 2 3 4 5 6 7 8 9 10 11 1 13 14 1 16 1 1 1 2 21 22
2 5 7 8 9 0
N L L E + - + - + - NC C NO NC C NO + - + - + -

110V 230V BUZZER 485

24VDC SENDER RECEIVER Contact 1 Contact 2 Opacity Dust
50/60HZ AC MODBUS
80mA Rate:5A/240VAC 4-20mA

Black (-)
White (+)

13 CR
14 V0+ V0- V1+ V1-

CEMS CEMS
External Relay DAS CH1 DAS CH2

5 9
COM NO

L 

Alarm Bell / Siren Horn

N  240VAC

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Dust & Opacity Analyzer D10

Control Unit OPACITY: 0-100% 149mm

D10 DUST: 0-4000TPM 64mm
245mm x 195mm
D/A Depth
100mm

Panel Cut-Out
225mm x 155mm

75mm
ALL FLANGES

1 2 3 4 5 6 7 8 9 10 11 1 13 14 1 16 1 1 1 2 21 22
2 5 7 8 9 0
N L L E + - + - + - N/C C N/O N/C C N/O + - + - + -

115V 230V ALARM Contact 1 Contact 2 Opacity Dust 485

SENDER RECEIVER
50/60HZ AC 24VDC/80mA Rate:5A/240VAC 4-20mA Modbus

Black wire (-)

White wire (+) Sender Receiver Black wire (-)
SDS-SV5 White wire (+)
SDR-RV4
Stack/
chimney

Sensor
Bracket

DESCRIPTION
CONTROL UNIT - Mild steel epoxy enclosure c/w power supply, setting up controls, horn muting switch,
normal, alarm and LCD indicators, output relay contacts and remote meter output.

SENDER UNIT - Weatherproof cast aluminium housing c/w Light Emitting Diode source and optical
system.

RECEIVER UNIT - Weatherproof cast aluminium housing c/w Light sensor.

COMPLETE SET comprises of: (complete set model: DM-LK-D10)

 Controller Unit, Model: DM-LK-D10-C - 01 unit
 Sender Unit, Model: SDS-LK-SV5 - 01 unit
 Receiver Unit, Model: SDR-LK-RV4 - 01 unit

PART NO: SPARE AND ACCESSORIES

BZ-NE-24V-WIRE Buzzer Unit
S-LK-SDM-SP20 Receiver Seal Kit
S-LK-SDM-SP21 Sender Seal Kit
S-LK-SDM-SB Sensor Bracket
RC-LK-IR71002-00 Recorder Unit
FAN-HPB-81S Auto Clean Blower set Unit, Model: 81 c/w Hose and Fitting

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

B.S. 2742M BRITISH STANDARD MINIATURE SMOKE CHART

0 (0% of density)

1 (20% of density)

2 (40% of density)

3 (60% of density)

4 (80% of density)

5 (100% of density)

Developed and Manufactured by LKS

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Dust & Opacity Analyzer D10

Distributor:

LKS (M) SDN. BHD.

Lot 15, Jalan Anggerik Mokara 31/63,
Kota Kemuning, 40460 Shah Alam, Selangor, Malaysia.
Tel: 603-5240 0822 Fax: 603-5240 0222
Web: www.lkssb.com.my
E-mail: [email protected]

Developed and Manufactured by LKS

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