Preferred Instruments Smoke Opacity Monitor Smoke... · AD D2 D1 = Over Fire Start Delay, D2 = Over Fire Stop Delay AD = Alarm Delay. SDI-JC-30D PREFERRED INSTRUMENTS SMOKE 190711

SDI-JC-30D rev. 12/17/08 page 1 of 19

Preferred Instruments 31-35 South Street, Danbury CT 06810 203-743-6741 www.preferredinstruments.com

JC-30D Smoke Opacity Monitor

Installation & Operation Instructions

Description

The JC-30D Smoke Opacity Monitor is a microprocessor-based Indicating Instrument with a single pass, smoke duct mounted, Light Source and light Detector. The JC-30D provides a high visibility backlit LCD opacity numeric display with bargraph, alarm indication and burner shutdown capability. The intuitive bargraph display with alarm messages provides rapid recognition of combustion conditions. The Light Source and Light Detector are mounted on opposite sides of the smoke duct. Smoke passing through the light beam reduces the light intensity being received by the Detector. The light intensity milliamp signal is transmitted to the JC-30D Indicating Instrument where it is scaled and then converted into Opacity. This reliable single pass design requires no moving parts or complicated optical devices. The Light Source uses a low voltage, pre-focused, sealed beam lamp with a projection angle of 5° to reduce scattered light inaccuracies. The Light Detector is a solid state, photopically filtered photoelectric cell. The unit’s built-in optical “bulls eye” and variable blink rate LED assist in alignment verification. Lenses are specially designed for easy cleaning without dismantling the installed assembly. Automatic Calibration (AutoCal) The JC-30D includes a 120 Vac input that can monitor the burner fan starter in order to initiate an AutoCal (Automatic Calibration) cycle after the burner fan stops running (ensuring a clear stack condition). This can prevent nuisance burner trips due to dust build-up on the optics. “CLEAN LENSE” is displayed after Auto-Cal if the Light Intensity is low (typically due to dust build-up on the optics). A Calibration Cycle can also be manually initiated from the JC-30D Menu (after a lens cleaning, re-alignment, etc.). If desired, AutoCal can be disabled from the JC-30D Menu. Field Selectable Alarm / Relay Sequences The JC-30D Menu allows the user to select one of three Sequences: STANDARD (default), NYC-BAR, or WOOD-COAL. STANDARD and NYC-BAR are intended for typical gas/oil burners, WOOD-COAL is intended for stoker fired boilers. The JC-30D has two relay outputs. For all three Sequences, Relay 1 is the Alarm Relay and it's contacts are used to activate an external bell, horn, light, or other alarm device. For the STANDARD or NYC-BAR Sequence, Relay 2 is a burner Shutdown relay. For the WOOD-COAL Sequence, Relay 2 is used to add Overfire Air in order to reduce the opacity level. The STANDARD Sequence has field adjustable Alarm and Shutdown time delays. The NYC-BAR (New York City Bureau of Air Resources) Sequence time delays are not adjustable and are set to 0 seconds Alarm delay and 120 seconds Shutdown delay. The WOOD-COAL time delays and setpoints are all field adjustable (see below).

SMOKEDUCT

LIGHT BEAM

LIGHTSOURCE

LIGHTDETECTOR


Table of Contents: Specifications......................................................................2 STANDARD Sequence.......................................................3 NYC-BAR Sequence ..........................................................4 WOOD-COAL Sequence ....................................................4 Installation...........................................................................5

JC-30D Indicator Mounting: ...........................................5 Light Source and Light Detector Mounting:....................5 Wiring:............................................................................7

Menus .................................................................................8 New Installation Setup ......................................................11

Bargraph, Contrast.......................................................11 Alarm Sequence, Setpoint, and Time Delays ..............11

Align Light Source & Setup GAIN Switches ................ 12 Opacity Calibration........................................................... 13

MenuCal ...................................................................... 14 AutoCal........................................................................ 14 Calibration Data........................................................... 14

Maintenance..................................................................... 15 Cleaning ...................................................................... 15 Light Source Bulb Replacement.................................. 15 Lamp Brightness Sensor Calibration........................... 15

Modbus Communications................................................. 16 Troubleshooting ............................................................... 16

Specifications

Panel Power Supply: 120Vac, +/- 15%, 50/60Hz, 15 VA Case Size: 8"H x 3.5"W x 7.5"D Enclosure Type: NEMA 12 faceplate, Indoor locations Ambient Temp.: +32° to 122° F Inputs Light Intensity: 4-8mA thru 4-20 mAdc, 100.5 ohm load 24 Vdc supplied by JC-30D Remote Silence: Isolated Dry Contact, 15 Vdc / 2 mA Burner Fan Status: 120 Vac / 10 mA, Optically Isolated Outputs Opacity: 4-20 mA, 650 ohm load Relay Outputs: 10 A Resistive, 8 FLA, ½ Hp, 120 Vac Communications: Modbus, ASCII or RTU RS485, 1200 - 38400 Baud

Light Source and Detector Calibration: Automatic, Off-Line Spectral Response: Photopic, peak and mean

within 500-600 nm Angle of Projection: < 5 degrees Operational Error: < 5% Calibration Error: <1% (Linearity) Response Time: < 10 seconds for 95% change Sighting Distance: 3 - 10 ft optical path length Ambient Temp.: +32° to 132° F Wiring Distance: 500 ft max. Mounting: ¾" pipe

Ordering Information: Part Number Description JC-30D Smoke Opacity Monitor, includes Indicator, 190711 Light Source, and 190712 Light Detector 107226P One pair of Pressure Caps with 1/8" NPT connection for Purge Air. 190275A One pair of Pressure Caps with integral 1.4" wc Blowers 190713 Ambient Light Shield. Recommended for all installations. (2 req’d: one for Source, one for Detector) SDA-VB Remote Audible / Visual Alarm, 120 Vac SDA-B6 Alarm Bell, 6" dia, 85 db, 120 Vac R88-E5 2-¼" Strip Chart Recorder, 31 day, 4-20 mA 21362 Light Source light bulb 190711 Replacement Light Source (complete) 190705-LS Light Source circuit board 190712 Replacement Light Detector (complete) 190705-DET Light Detector circuit board 21009 ¼ amp Slo-Blo, 250 V,3AG fuse 90265 Replacement LCD display 90248 Replacement Mylar Keyboard Overlay 90256 Panel Mounting Gasket NOTE: This manual revision applies to JC-30D software version 1.08 and Light Source Brightness software version 2.13.


STANDARD Sequence This description is based on the STANDARD Alarm Sequence. The NYC-BAR and WOOD-COAL Sequences are described in the next section. Opacity (Smoke Density) is continuously displayed at the top of the indicator in 0-100% Opacity units. The Bargraph height varies in proportion to the Opacity. The Bargraph scaling can be adjusted to any range between 0-20% and 0-100% Opacity (via the JC-30D Menu). The JC-30D Alarm Relay is typically wired to an external audible alarm (bell, horn, strobe,…). After Opacity has been above the Alarm Setpoint for 20 seconds (adjustable), the Alarm Relay energizes, and ALARM is displayed. The 'tic' mark on the right side of the Bargraph indicates the Alarm Setpoint. To silence an external audible alarm, press the Alarm Silence button (or close the remote alarm silence contact wired to terminal 3, or set Modbus coil 101 = 1). The Alarm Relay automatically de-energizes if the Opacity drops below the Alarm Setpoint. The JC-30D Shutdown Relay contacts are typically wired into the burner interlocks and will shutdown the burner if the Opacity has been above the Alarm Setpoint for more than 120 seconds (adjustable). The Alarm Relay re-energizes when Shutdown occurs, and can be silenced as described above. The Shutdown Relay remains de-energized, the burner will not re-start, and SHUTDOWN is displayed until the JC-30D has been RESET. The Opacity must be lower than the Alarm Setpoint before the RESET button is pressed. The Bargraph blinks while ALARM or SHUTDOWN is displayed. The Message Line displays the following scrolling messages:

LENS IS DIRTY During the last Clear Stack calibration cycle, the light intensity at the Detector was very low. The Light Source bulb, Detector lens, or pressure cap windows are probably dirty and should be cleaned ..or.. the Light Source was not properly aligned. The JC-30D must be re-calibrated after it is cleaned or re-aligned.

STRAY LIGHT OR ALIGNMENT ERROR The displayed Opacity has been negative for more than 30 seconds. More light is reaching the Detector than was present during the Clear Stack Calibration. Either the Light Source has been knocked out of alignment, or stray light from a nearby outside window or light fixture is reaching the Detector. The optional 190713 Light Shield should be installed to prevent this problem. The JC-30D must be re-calibrated after correcting the problem. The Stray Light Test Option is normally disabled, and is only enabled for troubleshooting. This option is enabled/disabled from the Calibration Sub-Menu.

The Message Line is also used to display messages described in the Auto-Cal section of this manual.

Alarm Relay

Shutdown Relay

Alarm Silence

Opacity

STANDARD Sequence

AD

SD

AD

Alarm Setpoint

Shutdown ResetButton

AD = Alarm Time Delay, SD = Shutdown Time Delay

Alarm Silence Button Opacity Alarm Setpoint Opacity Bargraph Shutdown Reset Button Message Line ALARM / SHUTDOWN Menu / Escape Button


NYC-BAR Sequence The NYC-BAR Sequence is the same as the STANDARD Sequence described above with two differences:

The Alarm Time Delay is fixed at 0 seconds and can not be adjusted. This means that the Alarm Relay will activate as soon as the Opacity is greater than the Alarm Setpoint.

The Shutdown Time Delay is fixed at 120 seconds and can not be adjusted.

A 20% Opacity Test Filter is attached to the Light Detector. An Inspector can hold this filter in the light beam to verify that the Alarm Setpoint is set correctly and that the calibration is reasonable. The 20% Opacity value of the filter is approximate.

WOOD-COAL Sequence The WOOD-COAL sequence is intended for use on solid fuel stoker fired furnaces. The Alarm Relay and Alarm Silence operation is the same as the STANDARD Sequence described above. The JC-30D WOOD-COAL logic for Relay 2 can be used to add Overfire Air (above the stoker) to reduce smoke caused by clinkers and other stoker problems. Relay 2 is typically wired to an Overfire Air fan starter, or motorized damper. The WOOD-COAL Sequence does not include any burner Shutdown logic. The Overfire Start Setpoint controls Relay 2, and is independent from the Alarm Setpoint. Typically, the Overfire Alarm Setpoint is set to a lower Opacity level than the Alarm Setpoint. If the Opacity is above the Overfire Start Setpoint for more than the Overfire Start Delay (10 seconds, adjustable), Relay 2 energizes and OVERFIRE ON is displayed on the message line. The Overfire Start Delay prevents nuisance starts due to momentary smoke puffs. Once Relay 2 is energized, the Opacity must be below the Overfire Start Setpoint for the Overfire Stop Delay (180 seconds, adjustable) before Relay 2 will de-energize. The Stop Delay helps prevent re-occurrence due to incomplete burn-out. WOOD-COAL Sequence Parameters. See the Menu Structure and Editing instructions below.

Actual Default Max. Min. ALARM SETUP Menu Items 12 50 1 OPACITY, OVERFIRE START SETPOINT

This Setpoint Starts and Stops the Overfire Air (for smoke reduction). Note: This value is ONLY used in WOOD-COAL mode.

10 120 1 SEC, OVERFIRE START DELAY The Overfire Air relay (Relay 2) energizes when the Opacity has been above the Overfire Start Setpoint for more than 'Overfire Start Delay' seconds. Note: This value is ONLY used in WOOD-COAL mode.

180 160 1 SEC, OVERFIRE STOP DELAY The Overfire Air relay (Relay 2) de-energizes when the Opacity has been below the Overfire Start Setpoint for more than 'Overfire Stop Delay' seconds. Note: This value is ONLY used in WOOD-COAL mode.

NOTE: If the JC-30D is not going to be wired to shutdown a burner, select the WOOD-COAL sequence and adjust the Over Fire Alarm settings as follows:

Over Fire Start Opacity Setpoint: 50% Over Fire Start Delay Seconds: 180 sec. Over Fire Stop Delay Seconds: 1 sec.

Using the WOOD-COAL sequence eliminates nuisance SHUTDOWN alarms, and automatically silences the Common Alarm when Opacity decreases.

NYC-BAR Sequence

Alarm Relay

Shutdown Relay

Alarm Silence

Opacity

120 sec (fixed)

Alarm Setpoint

Shutdown ResetButton

Alarm Relay

Over Fire AirRelay

Alarm Silence

Opacity

WOOD-COAL Sequence

D1

Alarm Setpoint

Over Fire Setpoint

D2 D1

AD

D2

D1 = Over Fire Start Delay, D2 = Over Fire Stop DelayAD = Alarm Delay


Installation

JC-30D Indicator Mounting: The JC-30D Indicator is designed for flush mounting in an enclosure located in an indoor NEMA 12 environment. The JC-30D should not be subjected to excessive vibration. Continuous operation is guaranteed within the 32-122 F (0-50C) ambient operating range. • Cut a rectangular hole and drill two 5/32" mounting holes in the panel. • If NEMA 12 water mist protection is required, apply the supplied gasket onto

the panel. • Remove the nuts from the JC-30D mounting studs. NOTE: Hold the JC-30D faceplate in place after the nuts are removed. • Put the JC-30D into the panel hole and re-install the nuts on the mounting

studs from the inside of the panel. Light Source and Light Detector Mounting: The Light Source and Detector are designed for mounting in an indoor NEMA 1 environment. The light Source and Detector should not be subjected to excessive vibration. Continuous operation is guaranteed within the 32-132 F (0-55C) ambient operating range. • Locate such that the light beam passes through the complete smoke profile at all flow rates.

See the sketch at right for locations after an Elbow, T, Fan, or other uneven profile. • Locate the Light Source and Detector as far away from other sources of bright light (outside

windows, light fixtures, …). • 190713 Light Shields for BOTH the Source and Detector are strongly recommended for all

installations. • Locate the Light Source and Detector where it is easily accessible for routine cleaning. • The distance from the face of the Light Source to the face of the Light Detector must be

greater than 3 ft. and less than 10 ft. • The ¾" mounting pipe should generally be horizontal to prevent overheating the Source or

Detector. The smoke duct may be vertical, horizontal, or any other angle. • The ¾" mounting pipe maintains the optical alignment from the Source to the Detector. The

flue gas heat expands and contracts the pipe length . One end of the mounting pipe must be free to move. Do NOT weld or rigidly connect BOTH ends of the mounting pipe.

• See the full size template on the next page for mounting dimensions. • For positive pressure ducts, install a pressure cap (ie, window) to prevent flue gas and dust

from exiting the duct. The 190226P pressure caps can be used without purge air for low soot installations. Clean, dry compressed air can be connected to 107226P pressure caps for dirtier installations. The 190275A Blower Caps is suitable for duct pressures less than +1.4" wc. See the 107226P or 190275A instructions for further details.

5/32 dia.(typ. 2)

PanelCutout

Dimensions

3.50

2.80

2 7/8

8.00 6.53

6 5/8

3/16

7.00

1 7/16

7.00

0.50

PREFERREDINSTRUMENTSDanbury, CT USA

MENU(ESC)

ALARMSILENCE

3/8 6-32 Stud(typ. 2)

SMOKEDUCT

LIGHT BEAM

190711LIGHT

SOURCE

190712LIGHT

DETECTOR

WELD or CLAMP

SLIDING FIT

3/4" PIPE

3' MIN / 10' MAX

10"CLEAR ANCE

12" 12"CLEAR ANCE

10"

NEGATIVE DUCT PRESSURE INSTALLATION

BEST

5 diam

eters

after

a be

nd

GOOD

GOOD

POOR

Mounting LocationsDownstream from an

Elbow, T, or Fan


Full SizeCutout Template

3 1/2

1 1/2

2

1-1/8" dia. for3/4" mounting pipe

2-1/2" dia. fornegative ducts

or 107226Ppressure caps

1/2" peephole(Light Source side only)

Hole forlight beam

2-1/8" dia. for190275A

Blower Caps

SMOKEDUCT

LIGHTSOURCE

LIGHTDETECTOR

3' MIN / 10' MAX

10"CLEAR ANCE CLEAR ANCE

10"

POSITIVE DUCT PRESSURE INSTALLATIONWITH 107226P PRESSURE CAPS

5"5" 5"5"

2-1/2" PIPE

107226PPRESSURE

CAP

1/8" NPT(OPTIONALPURGE AIR)

SMOKEDUCTLIGHT

SOURCELIGHT

DETECTOR

3' MIN / 10' MAXCLEAR ANCE

POSITIVE DUCT PRESSURE INSTALLATIONWITH 190275A BLOWER CAPS (<1.4" WC)

2" PIPE

190275ABLOWER

CAP

8"6"10" 8" 6" 10"CLEAR ANCE

12"

SMOKEDUCT

LIGHT BEAM

190711LIGHT

SOURCE

190712LIGHT

DETECTOR190713 AMBIENT LIGHT SHIELD

11"11"


Wiring:

Warning Disconnect all sources of power before installing or servicing this equipment. Multiple Disconnects may be required. Burner interface wiring must be performed by an experienced burner service technician.

All wiring must comply with all local and national electrical codes. Tighten all terminals to 4.4 in-lb. Wire must be stranded copper, 12-24 ga., 150V / 60 C insulation minimum. AC and DC wiring must be separated to prevent electrical noise coupling. Do not run AC and DC wires in the same conduits. Use shielded cables where shown, connect shields only where shown, insulate all other shields to prevent accidental grounding. Ignition transformer and motor VFD wiring are particularly noisy and should be kept away from all other AC and DC wiring. • The Light Source wiring must be installed with a flexible wiring loop to allow the Light Source enclosure to pivot

when the light beam is aimed at the Light Detector. • The wiring from the Light Detector to the Source must be kept as short as possible (20 ft max.) and must be

kept away from electrical noise sources. Do not run in conduits with AC wiring. • Inside the Light Source, insulate the bare shield wires so that they do not short to the enclosure or to any of the

components on the circuit board. • The optional Burner Fan status 120 Vac input wiring is required if the Auto-Cal feature is being used. • Relay contacts are shown with power removed from the JC-30D. In normal operation Relay 2 is energized.

Relay 2 de-energizes to shutdown the burner. • Relay contacts have internal surge suppressors and are rated: 10 A resistive, 8 FLA / ½ Hp / 120 Vac • All DC wiring is isolated from Ground. • All DC wiring '-', shield, and 'Common' terminals are connected together internally. • Terminals 1-9 are Line Voltage AC. Terminals 10-26 are low voltage DC. Fuse: ¼ amp Slo-Blo, 250 V,3AG (Preferred Instruments 21009, Littlefuse p/n 313 .250) Caution: To reduce the risk of fire, only replace fuse with the same type.

102324

111215

+24 Vdc

JC-30D Indicator

AKS

190711Light

Source

190712Light

Detector102324

1112

AK

Bulb On/Off-

-

LightIntensity

mASignal

+

1617-

+ Opacity 4-20 mA

WOOD-COAL Sequence Note:Relay 2 Energizes to add Over FireAir to the Furnace. Wire Relay 2 tothe Over Fire Air Motor Starter orDamper Actuator circuit.

12N

H120 Vac15 VA

50/60 Hz

252622

RS485 +RS485 -Common

Modbus RS485Communications

1920

Remote Alarm Silence Pushbutton-+

Note: 15 Vdc signal, do not run with AC wiring. Isolated 'dry' contact required.

456

Alarm RelayRelay 1

External AlarmCircuit

(Relay Energizes when in Alarm)

Optional

Shutdown Relay789

Burner LimitsCircuit

Relay 2

(Relay De-Energizes to Shutdown Burner)

3120 Vac

Burner FanStarter Coil

Optional

Auto-Calibration activateswhen fan stops

LIGHTSOURCEWIRINGLOOP(FOR

AIMING)


Menus

Calibration, Alarm Setpoint and time delay adjustment, Alarm Sequence selection, Bargraph scaling, LCD contrast adjustment and all other changes are made via the JC-30D Menus. This overview shows how to navigate through the JC-30D Menus and Sub-Menus. The detailed descriptions of each parameter will be discussed in the sections that follow. From the bargraph display, press the MENU button to activate the MAIN MENU. When in the Menus, the MENU button becomes the ESCape button. Pressing ESCape either cancels the current editing operation, or returns to the previous Menu, or exits the Main Menu and returns to the Bargraph display. The items inside the box in the middle of the screen are the current Menu line item. Items above or below this box are previews of the next Menu lines. Press UP or DOWN to scroll to the next Menu lines. Press SELECT to edit the value of the current item or to activate the Sub-Menu. Press ESC to exit a Menu or to cancel the editing of a value.

MORE Menu Lines are further up Preview of next Menu Line Press SELECT To GOTO this Sub-Menu Preview of next Menu Line

Menu Name Press SELECT To GOTO this Sub-Menu Current Menu Item Description of Current Line Preview of next Menu Line MORE Menu Lines are further down First press displays MAIN MENU. When in a Menu, press to ESCAPE from the Current Item or Menu.


Menu Structure JC-30D Smoke Opacity Monitor

JC30D MAIN MENU CALIBRATE ALARM SEQUENCE SETUP TOP OF BARGRAPH MODBUS LCD CONTRAST

CALIBRATE MENU GO TO CALIBRATE NOW AUTO-CAL AFTER FAN STOPS CLEAR STACK DELAY CLEAR STACK OPACITY MA CHANGE EQUALS SETTLED CAL MA FOR CLEAR STACK CAL MA FOR 100% OPACITY CAL CLEAR STACK OPACITY STRAY LIGHT OPTION

MODBUS SETUP MENU PROTOCOL:, ASCII, RTU xxx ADDRESS xxxx BAUD RATE (4800<->38400) PARITY, ODD, EVEN, NONE

ALARM SETUP MENU ALARM SEQUENCE ALARM SETPOINT ALARM DELAY SHUTDOWN DELAY OVERFIRE START SETPOINT OVERFIRE START DELAY OVERFIRE STOP DELAY

See the Calibration Section for Details


See the Calibration Section for Details

JC30D MAIN MENU CALIBRATE ALARM SEQUENCE SETUP TOP OF BARGRAPH MODBUS LCD CONTRAST

CALIBRATE MENU GO TO CALIBRATE NOW AUTO-CAL AFTER FAN STOPS CLEAR STACK DELAY CLEAR STACK OPACITY MA CHANGE EQUALS SETTLED CAL MA FOR CLEAR STACK CAL MA FOR 100% OPACITY CAL CLEAR STACK OPACITY STRAY LIGHT OPTION

MODBUS SETUP MENU PROTOCOL:, ASCII, RTU xxx ADDRESS xxxx BAUD RATE (4800<->38400) PARITY, ODD, EVEN, NONE

ALARM SETUP MENU ALARM SEQUENCE ALARM SETPOINT ALARM DELAY SHUTDOWN DELAY OVERFIRE START SETPOINT OVERFIRE START DELAY OVERFIRE STOP DELAY


New Installation Setup Bargraph, Contrast After installing the JC-30D, apply 120 Vac power, Select the Main Menu item: LCD CONTRAST, and adjust the contrast value to suit the installed viewing angle. The Light Source should be ON for at least a 10 minutes before Opacity Calibration can begin. If desired, change the TOP OF BARGRAPH opacity value (see below).

Actual Default Max. Min. JC30D MAIN Menu Items 40 100 20 OPACITY, TOP OF BARGRAPH

The Bargraph height can be scaled for any range between 0-20% and 0-100% for increased resolution. This value should be evenly divisible by 4 for easy-to-read scale values (displayed to the left of the bargraph). This value does NOT affect the JC-30D calibration. The JC-30D numeric display and the 4-20 mA output are always calibrated as 0-100% Opacity.

125 150 100 LCD CONTRAST Adjust this value for best contrast based on the installed viewing angle.

Alarm Sequence, Setpoint, and Time Delays Read the STANDARD, NYC-BAR and WOOD-COAL Sequence descriptions and then select the desired Sequence in the ALARM SETUP Menu. Set the ALARM SETPOINT, ALARM DELAY, and SHUTDOWN DELAY as determined by the operating conditions or as determined by local or national codes. See the notes for ALARM DELAY, and SHUTDOWN DELAY that explain how these delays are used, or not used, for each Sequence.

Actual Default Max. Min. ALARM SETUP Menu Items STANDARD ALARM SEQUENCE

STANDARD: Typical burner, Alarm and Shutdown time delays are adjustable.

NYC-BAR: New York City Bureau of Air Resources. Typical burner. Time delays are not adjustable and are fixed at: 0 sec Alarm delay and 120 sec Shutdown delay WOOD-COAL: Stoker fired furnace. Relay 2 is used to add Overfire Air,

see sequence description above. 20 50 5 OPACITY, ALARM SETPOINT

This Setpoint is used for both the Alarm logic and for the Shutdown logic. 20 120 0 SEC, ALARM DELAY

The Alarm relay (Relay 1) energizes when the Opacity has been above the Alarm Setpoint for more than 'Alarm Delay' seconds. Note: In NYC-BAR mode, this value is ignored. The Alarm Delay is fixed at 0 seconds.

120 180 0 SEC, SHUTDOWN DELAY The Shutdown relay (Relay 2) de-energizes when the Opacity has been above the Alarm Setpoint for more than 'Shutdown Delay' seconds. The Opacity must drop below the Alarm Setpoint and the Operator must press the RESET button in order to re-energize the Shutdown relay. Note: In NYC-BAR mode, this value is ignored. The Shutdown Delay is fixed at 120 seconds. Note: In WOOD-COAL mode, this value is ignored (No Shutdown logic).


Align Light Source & Setup GAIN Switches The Light Source circuit board amplifies the Detector Light Intensity signal and transmits it to the indicator as milliamp signal. The amplifier has 4 switch selectable Gain settings that compensate for the installed optical path length and losses due to pressure cap windows. The GAIN switch setup should only be done during initial start-up or after replacing the Light Source Bulb. The GAIN switches should NOT be re-adjusted after routine lens cleaning or re-alignment. This procedure can be accomplished by watching the Light Intensity LED blink rate (OFF means less than 10 mA, steady ON means greater than 20 mA). However, connecting a 0-25 mA meter in series with the light intensity signal (as shown at right) makes it easier to optimize the Light Intensity level that is reaching the Light Detector. 1) Inspect the Light Source and Detector to verify that bright light from a window or light fixture

will not shine or reflect into the either the Source or Detector. If necessary, install 190713 (or equal) light shields over the Source and Detector.

2) With Burner OFF: Clean the Light Source bulb, Detector lens, and any Pressure Cap windows. 3) Slightly loosen the pivot bolts on the sides and the top of the Light Source. 4) Open the Light Source rear door.

Set SW3 (LAMP) to ON (This forces the bulb to turn ON). 5) Wait 5-15 minutes for the Lamp to warm up. This allows the Lamp Brightness to stabilize.

If the Lamp Brightness Sensor Green LED is OFF, or blinking, re-calibrate the Lamp Brightness Sensor as described below (pg 14).

6) Set GAIN = 4 (SW1 = OFF, SW2=OFF) 7) Aim the Light Source for the highest Light Intensity.

The LED at the bottom of the Light Source blinks faster for a higher light intensity. A higher milliamp signal indicates a higher light intensity. NOTE: The milliamp signal lags about 2 seconds behind the light beam, move the Light Source very slowly during a alignment to prevent over shooting the peak signal position. NOTE: The light beam pattern is like a doughnut, darker in the middle with a brighter circular band around the middle. It may be necessary to aim the bulb off-center in order to have the bright outer band on the detector for the maximum milliamp signal. At the best alignment, If the LED is blinking (10 mA < Light Intensity < 20 mA), go to step 11). At the best alignment, If the LED is ON and not blinking ( > 20 mA), proceed to step 8).

8) Set GAIN = 2, (SW1=OFF, SW2=ON), then Aim the Source for the highest Light Intensity. At the best alignment, If the LED is blinking (10 mA < Light Intensity < 20 mA), go to step 11). At the best alignment, If the LED is ON and not blinking ( > 20 mA), proceed to step 9).

9) Set GAIN = 1, (SW1=ON, SW2=OFF), then Aim the Source for the highest Light Intensity. At the best alignment, If the LED is blinking (10 mA < Light Intensity < 20 mA), go to step 11). At the best alignment, If the LED is ON and not blinking ( > 20 mA), proceed to step 10).

10) Set GAIN = .5, (SW1=ON, SW2=ON), then Aim the Source for the highest Light Intensity. 11) At the best alignment (highest mA signal):

If the LED is blinking (10 mA < Light Intensity < 20 mA), go to step 12). If the LED is ON and not blinking ( > 20 mA), purposely mis-align the Light Source until

the LED blinks (to reduce the Light Intensity), then go to step 12). If the LED is OFF, and the signal is greater than 8.5 mA, go to step 12). If the LED is OFF, and the signal is less than 8.5 mA, Calibration will not be successful.

Attempt to align the Detector or clean the optics to achieve a higher Intensity. Verify that the optical path length is less than 10 ft. Verify that the mounting dimensions and stack hole sizes are correct. The Intensity signal must be greater than 8.5 mA before proceeding.

12) Carefully, and very firmly, tighten the pivot bolts without changing the alignment. 13) Set SW3 (LAMP) to OFF (Auto). 14) Close the Light Source door. 15) Calibrate from JC-30D menu as described below.

111215

LightSource

1112 -

Light Intensity mA Signal Wiring

+

JC-30D

111215

1112 -

Test Meter mA Hook-Up

+

JC-30D

DC mA

A+

V+ -

BrightnessSensor LED

Light Intensity Blinking LED

SW2

SW1

SW3


Opacity Calibration Calibration can either be manually initiated by the operator from the CALIBRATE Menu (MenuCal), or automatically after the burner fan stops (AutoCal). This section defines terminology and describes the Opacity Calibration process.. The Lamp Brightness Sensor must be within calibration range before attempting to calibrate the JC-30D (see pg 14). If the Red Light Intenstiy LED on the outside bottom of the Light source is blinking like pause-2 blinks-pause or pause-4 blinks-pause, the Lamp Brightness Sensor is out of calibration and must be re-calibbrated before starting the JC-30D calibration (see pg 14). Opacity Calibration can not start unless the Light Source Bulb has been turned ON by the JC-30D for at least a 3 minute Light Bulb Warm-up (however, 5-15 minutes is recommended). Activating the bulb override switch (SW3) in the Light Source does not count towards the 3 minute warm-up time. Clear Stack Delay starts when the burner fan input turns OFF, and provides time for the dust in the stack to clear, and for inlet or outlet dampers to close after the burner fan has stopped. Opacity Calibration will not start until after the Clear Stack Delay timer has expired. Adjust this time to suit the operation of the furnace, burner, dampers. 100% Opacity means that none of the light from the Light Source is reaching the Light Detector. The JC-30D turns off the Light Source to calibrate 100% Opacity. 0% Opacity means that all of the light from the Light Source is reaching the Light Detector, and absolutely NO dust, soot, or unburned fuel is obstructing the light beam. The burner must be shutdown and the furnace must be cold in order to have 0% Opacity. If the burner is shutdown, and the furnace is warm, there will be some dust being carried up the stack by the draft. Clear Stack Opacity is the % Opacity used to calibrate the JC-30D. The default value is 2% opacity, based on the assumption that the furnace is warm and that there are still low levels of dust in the duct. This value can be adjusted to 0-4% via the Calibration Menu. The Calibration Sequence can be activated either by the operator selecting GOTO CALIBRATE NOW from the CALIBRATE Menu (MenuCal), or automatically after the burner fan stops (AutoCal). The calibration sequence is the same for either a MenuCal or an AutoCal activated calibration and is shown in the diagram. During calibration, the JC-30D calculates a running averages of the 4-20 mA Light Intensity signal over 10 second periods. At the end of each 10 seconds, the JC-30D finds the % change between the current and previous period. The average mA value is stored in the calibration memory when the % change is less than +/- 0.30% (adjustable) for two consecutive periods. The Settled Percent is entered in the Calibrate Menu (PERCENT, MA CHANGE EQUALS SETTLED). The settling process typically takes 1-3 minutes each for Clear Stack and 100%. The calibration will abort if the mA value does not settle within 10 minutes. If the Settled Percent is too small, Calibration may never complete. If Settled Percent is too large, the Calibration might complete before the mA signal finally settles and this could cause errors in the Opacity display.

Actual Default Max. Min. CALIBRATE Menu Items 30 600 30 SEC, CLEAR STACK DELAY

This delay provides time for the dust in the stack to clear out after the burner fan has stopped.

2 4 0 PERCENT, CLEAR STACK OPACITY Typically there is always some floating dust (opacity) in 'clear' stack. This value is the 'clear' stack opacity that will be used during calibration.

0.30 0.60 0.01 PERCENT, MA CHANGE EQUALS SETTLED The change between two 10 second averages must be less than this % before the light intensity is considered 'settled' at it's final value during calibration.

Auto-Calibration Sequence with BulbSaver Enabled

Light Source

Signal Sampling

Clear Stack DelayBurner Fan

10 min. warm-upBulbSaver

100% Opacity CalibrationClear Stack Calibration


MenuCal Calibration can be manually initiated by going into the CALIBRATE Menu and selecting the GOTO CALIBRATE NOW line item. The Burner fan should be OFF and the stack must be clear. • The screen at right is displayed until the Bulb Warm and Clear Stack time delays expire. • The DETECTOR (ie, Light Intensity) must be higher 8.5 mA. If less than 8.5 mA, clean the

optics. If the signal is still low, re-align the Light Source until the signal is at it's highest possible value (however, the signal must be less than 21 mA).

• Press the ENTER button to start the calibration sequence. However, do not press ENTER if you wish to use this screen as a diagnostic tool to display the DETECTOR mA (ie, Light Intensity).

• The screen below is displayed until the "Clear Stack" mA signal settles at it's final value. • The JC-30D then turns OFF the Light Source. • The screen below is displayed until the "100% Opacity" mA signal settles at it's final value. • CALIBRATION COMPLETE is then displayed • Press ESC to return to the Calibrate Menu • An error message will be displayed if the calibration aborts for any reason.

Press the ESC button at any time during the calibration sequence to abort the Calibration and return to the Calibrate Menu. AutoCal Set AUTO-CAL AFTER FAN STOPS equal to YES (in the Calibrate Menu) to enable AutoCal. If all of the following are true, AutoCal occurs after the burner fan stops: • The Clear Stack delay timer has expired • The 3 minute bulb warm-up time has expired • It has been more than 1 hour since the last successful AutoCal During AutoCal the main bargraph screen message line displays AUTOCAL IN PROGRESS. When AutoCal complete, either AUTOCAL OK or an error message is displayed. Press the Alarm Silence button to clear these messages. MenuCal overrides an AutoCal. Proper Installation is essential for successful AutoCal operation. Insure that the mounting pipe is only secured on one side and that all mounting clamps and alignment pivot screws are firmly tightened. 190713 Light Shields are strongly recommended to prevent calibration errors due to stray light. Calibration Data The Light Intensity mA values saved during calibration and the Clear Stack Opacity calibration value can be viewed in the Calibrate Menu. These values should not be changed by the user.

Actual Default Max. Min. CALIBRATE Menu Items NO YES NO AUTOCAL AFTER FAN STOPS

'YES' causes the JC-30D to automatically re-calibrate itself after the burner fan stops (once per hour, max)

20.000 21.000 8.000 MA, CAL MA FOR CLEAR STACK The 'Clear' Stack Light Detector milliamp signal for the current calibration. This value is for troubleshooting and can not be changed by the user.

4.000 4.700 3.900 MA, CAL MA FOR 100% OPACITY The 100% Opacity (ie, Bulb is OFF) Light Detector milliamp signal for the current calibration. This value is for troubleshooting and can not be changed by the user.

2 4 0 PERCENT, CAL CLEAR STACK OPACITY The 'Clear' Stack Opacity value for the current calibration. This value is for troubleshooting and can not be changed by the user.


Maintenance Cleaning The Light Source Bulb, Light Detector, and any Purge Cap windows should be cleaned periodically. Use a soft , lint free cloth dampened with "Windex". Wipe dry. Try to not change the Light Source Alignment. Re-calibrate from the CALIBRATE Menu after every cleaning. NOTE: If AutoCal is enabled, the time between cleanings will be much longer because AutoCal will calibrate out the normal dust build-up on the optical surfaces. CAUTION: On units with pressure caps, make certain the burner is OFF before cleaning the inside of the pressure cap windows. After cleaning, firmly press the pressure caps against the pipe and re-tighten the mounting screws. Light Source Bulb Replacement • Remove 120 Vac power from the JC-30D (Note: This will cause the burner Shutdown relay to de-energize). • Install the new p/n 21362 bulb and connect the two wires to the new bulb (either wire to either bulb terminal). • The new bulb will not have the same optical alignment as the old bulb. • Apply 120 Vac power to the JC-30D. Wait at least 5 minutes for the bulb to warm up. • Calibrate the Lamp Brightness Sensor, as described below. • Align the Light Source as described in the "New Installation Setup" section. • Re-calibrate the JC-30D from the CALIBRATE Menu as described above in the

Opacity Calibration section. • New bulb brightness can drfit substantially for the first 5-10 days and may require

frequent Lamp Brightness and JC-30D calibrations during this period. Lamp Brightness Sensor Calibration Lamp brightness varies as a light bulb ages. If the Lamp Brightness changes, the Opacity reading will be incorrect until the Opacity Monitor is re-calibrated. The rev G Light Source has a Brightness Sensor that trims the Lamp voltage in order to maintain a constant Lamp Brightness. The trim range is limited to +/-0.15 V from the nominal 3.25 V Lamp voltage. When is Brightness Sensor Calibration Required? It needs to be re-calibrated whenever the Lamp is replaced. It also needs to be re-calibrated when the Lamp aging dims the brightness more than the sensor can correct for. The internal green LED and the external red LED will blinks: pause-2 blinks-pause when the trim voltage is nearly out of range, but is still trimming. The blink pattern pause-4 blinks-pause indicates that the Brightness Sensor trim is out of range and must be re-calibrated. The Opacity reading will start to gradually drift when the Brightness Sensor has stopped trimming lamp voltage (even after the Opacity Monitor has been calibrated). NOTE: Excessive ambient light striking either the Detector or the Light Source Brightness Sensor is frequently the cause of Opacity display drift. Install 190713 light shields over both the Source and the Detector to eliminate excessive ambient light. Brightness Sensor Calibration Procedure: 1) The Lamp should be ON for at least 5-15 minutes before calibrating the Brightness Sensor

(to allow Lamp brightness to stabilize). 2) Open the rear door of the Light Source. 3) Press and hold the Calibration Pushbutton, this will turn OFF the green LED. 4) Rotate the Calibration Pot until the Green LED turns ON. 5) Release the Calibration Pushbutton, the green LED should remain ON. 6) If the Green LED turns blinks after releasing the Pushbutton,

repeat the Pot adjustment until the Green LED remains ON after releasing the Pushbutton. 7) Carefully close the rear door of the Light Source. Do not knock the Light Source out of Alignment. 8) Use the JC-30D Menu to activate the automatic Opacity Calibration, as described in the JC-30D Instruction Manual.

Calibration Pushbutton

Calibration Pot

Brightness Sensor


Modbus Communications Field Selectable via the MODBUS menu: Protocol: RTU or ASCII Address: 1-247 Baud: 1200, 4800, 9600, 19200, 38400 Parity: Odd, Even, None ('No Parity' requires 2 Stop bits) Register Format: Signed Integers, -32767 to + 32767 Modbus Commands: 01 Read Coils, 03 Read Holding Registers, 05 Write Single Coil, 06 Write Single Holding Register (A maximum of 10 coils or registers can be read in a single poll)

Coil 0 = 1 = Description 300 RW Silenced Alarm Silence 301 RO Energized Alarm Relay 302 RO Alarm Opacity Alarm 303 RO Shutdown Shutdown 304 RO Energized Overfire Relay 305 RO Dirty Lens is Dirty

Register JC-30

Value Modbus

Value

40370 RO 100 % 100 Opacity 40322 RW 100 % 100 Alarm Setpoint 40323 RW 100 seconds 100 Alarm Time Delay Seconds 40324 RW 100 seconds 100 Shutdown Delay Seconds 40325 RW 100 % 100 Overfire Start Opacity Setpoint 40326 RW 100 seconds 100 Overfire Start Delay Seconds 40327 RW 100 seconds 100 Overfire Stop Delay Seconds

Troubleshooting

Normal Operation: Light bulb voltage: 3.25 volts (Bulb is not especially bright in normal operation) Terminal 10(+) to terminal 12(-): 19 - 26 Vdc range, 110-150 mA current draw (with Light Source ON) Lamp Brightness Sensor Green LED is ON. Bulb must be ON for at least 5 minutes to warm up. Light Intensity (term. 11) with light bulb OFF: 4.3 mA typical

"100% Opacity" calibration will fail if signal is outside the 3.9 - 4.7 mA range Light Intensity (term. 11) with light bulb ON: 8.5 - 21 mA range is OK

Varies based on distance from Source to Detector, GAIN setting in Source, dirt build-up on optics, and alignment. Shorter distances, larger GAIN setting, clean optics, better alignment relate to higher Light Intensity signal mA values.

"Clear Stack" calibration will fail if signal is outside the 8.0 - 21.0 mA range "Clear Stack" signals in the 8.0 - 8.5 mA range will calibrate successfully; however, LENS IS DIRTY will be displayed.

JC-30 assumes dirt build-up is the reason. If optics are clean, re-align and re-calibrate Light Source blinking red LED: Blinks faster for more Light, < 10 mA = OFF, > 20 mA = steady ON NOTE: To measure the Light Intensity mA signal coming into the JC-30D, select the GO TO CALIBRATE NOW screen in the Menus and observe the DETECTOR MA value on the screen: however, do not press ENTER to avoid starting the calibration process. Press ESC to exit this screen. Alternatively, an external milliamp test meter can be used.


Troubleshooting (continued) Refer to the wiring diagram on page 7. Check for each Symptom in the order shown (top to bottom), and then check each Potential Problem (for that Symptom) in the order shown (top to bottom). Symptom Potential Problems Comments / Tests JC-30D display is completely dark 120 Vac not present on terminals 1 & 2. JC-30D fuse is blown Possible field wiring direct short or overload from JC30 term 10 (24 Vdc) to

any "-" terminal. JC-30D term. 10 to 12 is less than 17 Vdc AC Line voltage is low.

Field wiring error (partial short) is drawing more than 150 mA from term. 10, remove all field wiring from JC-30D and re-test 24 Vdc at term. 10.

If wiring tests OK, possible defective Light source LCD glass is broken JC-30D Indicator is defective JC-30D display is lit up, but barely visible LCD display contrast setting. Re-adjust the LCD CONTRAST from the Main Menu. Light Source Bulb is OFF Light Source term. 10 to 24 is less than 17 Vdc Check for field wiring errors or loose connections. Bare shield wire is shorting to exposed components inside the

Light Source circuit board. Insulate shields, per Wiring instructions above. Possible permanent damage to PC board.

Light Source term. 23 to 24 at the Light Source > 8 Vdc (Lamp ON/OFF control circuit)

Field wiring error. JC-30D is not commanding the Bulb to turn ON

Normal, if "100% opacity" calibration is in progress With field wiring connected, short term. 23 to 24 at JC-30D

If volts at Light Source doesn't drop to near 0 Vdc, field wiring is open. If volts at Light Source drop to near 0 Vdc, JC-30D output is bad

Terminal 10 > 17 Vdc, Terminal 23 < 1 Vdc: Bulb terminal volts = approx. 3.25 Vdc, green LED is ON

Bulb Blown. Disconnect one bulb wire, measure bulb continuity.

Terminal 10 > 17 Vdc, Terminal 23 < 1 Vdc: Bulb wire volts near 0 Vdc or near 20 Vdc (with one wire diconnected from the bulb)

Bad Light Source circuit board


Troubleshooting (continued) Symptom Potential Problems Comments / Tests CLEAR STACK (max. light) calibration fails Bare shield wire is shorting to exposed components inside the

Light Source circuit board. Insulate shields, per Wiring instructions above. Possible permanent damage to PC board.

DETECTOR MA near 0 mA Open circuit in term. 11 wiring. 'A' or 'K' wires from Source to Detector open or cross wired.

Shine a flashlight into the Detector, Current in terminal 11 wire should increase with more light and should be > 3.7 mA.

If more light decreases the current, the 'A' and 'K' wires are swapped. Light Source circuit board or Detector might be bad.

DETECTOR MA near 4 mA Light Bulb is not ON. 'A' or 'K' wires from Source to Detector open or cross wired. Test Detector with flashlight as described in 'DETECTOR MA near 0 mA'.

DETECTOR MA less than 8.0 mA Light Source and Detector are more than 10 ft apart. Clean the optics, if necessary re-align the Light Source, and then

re-calibrate the JC-30. If this is new installation, was the "Setup GAIN Switches" procedure done?

DETECTOR MA greater than approx. 25 mA Field wiring short or error. +24 Vdc is shorting to JC-30D term. 11

DETECTOR MA greater than 21 mA Less than 3 ft between Source and Detector. Stray Light, see STRAY LIGHT troubleshooting below. Light bulb is brighter than a normal bulb.

Wrong bulb? ('4546' should be stamped on bulb). Light bulb voltage > 3.35 Vdc, replace Light Source circuit board. Brighter than normal bulb, purposely mis-align to lower signal.

CLEAR STACK calibration signal does not Settle within 10 minutes

Bulb Brightness Sensor is not trimming bulb voltage. Re-calibrate the Light Source Bulb Brightness Sensor.

Stray light Variations Install temporary light shields (ie, card board box) over the Light Source and Detector and repeat calibration

Light Source/Detector is changing alignment as the stack cools down.

Re-Tighten all pipe clamps, pivot bolts (for aiming) Check for mounting pipe vibration or movement. Light Source/Detector mounting pipe must not be welded or restrained on

both sides of the stack to allow expansion/contraction without bending the pipe (See installation instructions).

Light Source/Detector mounting pipe must be a continuous pipe running through the stack. Stubs mounted on each side can change alignment as the stack cools down.

Electrical noise Verify that all shields are only connected where shown, all other shields


Troubleshooting (continued) Symptom Potential Problems Comments / Tests 100% OPACITY (no light) calibration fails DETECTOR MA less than 3.7 mA Open circuit in term. 11 wiring.

'A' or 'K' wires from Source to Detector open or cross wired. DETECTOR MA greater than 8.0 mA JC-30D commanded the bulb to turn OFF; however, it is still ON:

SW3 in the Light Source was left in the ON position. Light Source term. 23 shorted to '-'

Stray Light, see STRAY LIGHT troubleshooting below. DETECTOR MA between 4.7 mA and 8.0 mA Stray light from a nearby outside window or light fixture is reaching the

Detector. The optional 190713 Light Shield can prevent this problem. Re-calibrate the JC-30D after correcting the problem.

100% OPACITY calibration signal does not Settle within 10 minutes

Electrical noise Verify that all shields are only connected where shown, all other shields

Burner is Shutdown and will not re-start SHUTDOWN is displayed, Opacity IS below the Alarm Setpoint Press the RESET button. SHUTDOWN is displayed,

Opacity IS NOT below the Alarm Setpoint Is the furnace smoking? Clean the optics, if necessary re-align the Light Source, and then

re-calibrate the JC-30. Opacity greater than 100% Out of alignment or not calibrated Align and re-calibrate Negative Opacity. STRAY LIGHT OR ALIGNMENT ERROR.

More light is reaching the Detector than was present during the Clear Stack Calibration.

Dirty optics were recently cleaned. The Light Source was been knocked out of alignment. Re-calibrate the JC-30D

Stray Light Stray light from a nearby outside window or light fixture is reaching the Detector, or has stopped reaching the Light Source Brightness Sensor. 190713 Light Shields, on both sides, can prevent this problem. Re-calibrate the JC-30D after correcting the problem.

Opacity reading drifts from day to night Stray light 190713 Light Shields, on both sides, can prevent this problem. Re-calibrate the JC-30D after correcting the problem.

Opacity reading drifts higher and higher over several days.

Dirt build-up on Source, Detector, or Pressure Caps. Clean all glass surfaces, Re-calibrate. Install purged pressure caps (compressed air or electric blower)

Bulb Brightness Sensor is not trimming bulb voltage. Re-calibrate the Light Source Bulb Brightness Sensor. Will not start an AutoCal cycle The burner fan running 120 Vac signal is not wired to term. 3 This input is required for AutoCal. The minimum interval between AutoCal's is one hour. AutoCal starts, but does not complete Manually intiate a Calibration cycle from the CALIBRATE Menu

to insure that Calibration is possible. Follow the troubleshooting guide above if any problems are encountered

during the manually initiated calibration cycle. Preferred Instruments 31-35 South Street, Danbury, CT 06810

203-743-6741 www.preferredinstruments.com

Documents

Preferred Instruments Smoke Opacity Monitor Smoke... · AD D2 D1 = Over Fire Start Delay, D2 = Over Fire Stop Delay AD = Alarm Delay. SDI-JC-30D PREFERRED INSTRUMENTS SMOKE 190711