sm-202 Manual V1.01

SM-202 Continuous Opacity Monitor Manual V1
Contents
Contents .........................................................................................................................1
Warnings ........................................................................................................................2
Physical Mounting .........................................................................................................3
Locating the sensing heads ........................................................................................3
Assessing temperature protection ..............................................................................5
Mounting the sensing heads .......................................................................................7
Installing an air purge system ....................................................................................8
Mounting the control unit ..........................................................................................8
Running the cable .......................................................................................................9
Wiring ..........................................................................................................................10
Power supply wiring ................................................................................................10
Control unit to RX wiring (interconnecting cable) ..................................................10
RX to TX wiring (main cable) .................................................................................11
Ancillary wiring .......................................................................................................11
Alarm and fault relay ...........................................................................................11
Analogue outputs .................................................................................................12
Set-up and commissioning ...........................................................................................13
Power-up ..................................................................................................................13
Setting the gain.........................................................................................................13
Choosing the unit of measurement ..........................................................................14
The Adjust function .................................................................................................15
Damping...................................................................................................................15
Alarm level...............................................................................................................16
Analogue out put ......................................................................................................16
Routine checks and maintenance .................................................................................17
Lenses...................................................................................................................17
Transmitter LED ..................................................................................................17
Fault finding.................................................................................................................18
Fault messages .........................................................................................................18
Appendix A – Operator interface familiarity...............................................................19
Appendix B – Pages (the operating system) ................................................................20
Switching between pages.........................................................................................20
Page 0 .......................................................................................................................20
Page 0 parameters ................................................................................................20
Page 1 .......................................................................................................................21
Page 1 parameters ....................................................................................................22
Appendix C - Recommended spares ............................................................................23
Appendix D - Principle of operation............................................................................24
Appendix E – Wiring details........................................................................................25
1
Warnings
The SM-202 Continuous Opacity Monitor operates on mains voltage (up to 265Vac)
electricity, capable of delivering an electric shock. The control unit must always be
electrically isolated before removing the back cover or working inside the
instrument. We recommend that the unit is electrically isolated at all times during
installation. Please check that all the wiring connections throughout the instrument
are correct and properly made, and ensure that the power supply to the instrument is
properly fused, as wiring errors in any part of the system can cause damage to SM-
202 components.
Installation must be completed by qualified personnel, in accordance with this

manual, and with regard to any local, regional, or national regulations applicable to
the installation and operation of this type of equipment.
The environmental ratings of this instrument only apply when the instrument is
properly installed, all lids, panels, and covers are securely fitted, and all cable glands
tightened to appropriate size cable.
We recommend that you read the appendix describing the principle of operation
before attempting to install or operate this equipment, as we feel that this will help
understand the considerations made when writing this manual.
2
Physical Mounting
All aspects of installation, whether electrical or mechanical, should be carried out

by qualified engineers.
It is very important that the installation of your SM-202 is planned out carefully in
advance of its implementation. Please study this section carefully before attempting to
install your SM-202.
Locating the sensing heads
Points to be considered:
• Legislation
• Accessibility
• Vibration
• Temperature
• Airflow
• Rain and condensing steam
• Cable lengths
Legislation: Legislation may apply to this installation and may specify, or make
specific requirements on, the placement of the sensing heads. If legislation does affect
the location of the sensing heads, priority must be given to the requirements made by
that legislation, but please do not disregard other considerations discussed here.
Accessibility: Access to the back of both sensing heads should be easily available, so
positioning at the level of a gantry or platform is preferable.
Vibration: Excessive vibration will cause movement of the optical beam which in
turn may cause a false opacity reading, so the heads must be mounted securely on a
sturdy section of the duct or stack.
Temperature: Both the external surface temperature of the duct and the ambient air
temperature should be assessed carefully when choosing a location for the sensing
heads. The external temperature of the duct should be no less than -100°C and no
greater than 500°C, although at less than -20°C and greater than 50°C heat insulation
equipment will be needed. Ambient air temperature should be no less than -20°C and
no greater than 60°C. If the ambient air temperature is being affected by radiated heat
from the duct, the use of lagging on the duct or a heat deflector plate in front of the
heads should be considered. It is important to try and pick a location for the sensing
heads which minimises their exposure to extreme temperatures. See the next section
on “Assessing temperature protection” if extreme temperatures are unavoidable.
3
Airflow: Airflow is a major

Duct
consideration in locating the
Duct
heads. Major deviation to the Bend
Increase
pattern of airflow can cause
4 duct widths 4 duct widths

erratic readings from the TX RX TX RX
instrument, consequently, the
4 duct widths
heads should be placed at
least 4 duct diameters away Reduction
Gas flow
from any such deviations,
particularly if the deviation is Bend Duct
upstream of the heads. TX RX Gas flow
Deviations can be caused by
4 duct widths
bends, increases or decreases Intrusion
or
sampling
in duct diameter, fans, point Inlet
or
junctions, dampers, inlets or Outlet
Duct
outlets, intrusions to the gas Gas flow

TX RX
flow, or extraction points for Duct
4 duct widths
other instruments (see right). TX
Gas flow
RX
The heads should never be

mounted top and bottom of a 4 duct widths
horizontal stretch of duct, as Fan

Junction
particulate will fall into the

purge unit of the lower head Gas flow
under the force of gravity.
Rain and condensing steam: These elements

passing through the optical path of the
instrument can cause a false reading. On hot
processes with a moisture content in the flue
gas, you will often get condensation of the
moisture content inside the stack shortly before
Rain
the gas flow exhausts into the cooler
4 duct wiadths
atmosphere, therefore it is very important that
Duct you assess the condensation point of your stack
RX
or duct and make sure that the heads are
TX Bad position
mounted upstream of this point. It is important
to remember that the condensation point will
RX
TX Good position move further into the stack as atmospheric
conditions change. As a general rule you
should place the heads at least 4 stack widths
Gas flow
away from the exhaust point. Scrubbers and
steam traps can also produce momentarily
condensed steam, which will also affect the
reading so the heads should be at least 4 duct widths away from any such equipment.
Rain can be a problem (see left), particularly on wide vertical exhaust stacks, where it
falls down through the light path, creating an artificial reading. On hot processes the
rain droplets will usually be evaporated shortly after entering the stack, so following
the rule of keeping the heads 4 stack widths away from the exhaust will normally
prevent the rain droplets causing a problem.
4
Cable lengths: The cable length

between the two sensing heads Duct
RX TX
must not exceed 25m, and the
cable length from the sensing
heads to the control unit must not
exceed 100m (see right),
although shorter cable lengths are 25m max. Interconnect cable
preferable. The cable route
should also be considered. You
should avoid laying the SM-202
Main cable
100m max.
cables over or alongside anything
which may emit electromagnetic Control unit
or RF signals, such as heavy OPACITY MONITOR
power cables or switch gear !
cabling. Tight bends, pinching,

clamping, and the possibility of
wear or abrasion should also be
avoided.
Taking all the above points into consideration you should be able to make a
considered decision on the best location for the sensing heads, however, if you find
that you cannot satisfy all the recommended criteria please make a sensible
compromise, rather than disregard one point altogether.
Assessing temperature protection
Most processes on which the opacity monitor will be employed are hot processes, and
it is therefore important to consider the effects of temperature and any protection that
may be required before mounting the sensing heads.
The best protection against the effects of heat is to mount the heads on a section of
duct, which is cool or at ambient temperature. However, where that is not possible,
you should consider the following.
The first aspect to be considered is the external

no insulating fl ange temperature of the duct wall to which you will be
Duct wall
mounting the sensing heads, as heat will transfer
-20 to +50deg.C from the wall through the mountings and into the
sensing head. If the duct wall is 50°C or more it
will be necessary to fit an insulating flange
Duct wall (available from DynOptic Systems Ltd) between
50 to 250deg.C the duct mounting and the head body. If the
external temperature is more than 250°C then 2
1 insulating flange
insulating flanges will be required (see left). The
Duct wall
250 to 500deg.C
maximum external duct temperature
recommended is 500°C.
2 insulating flanges
5
Flue gas temperature is not a

critical aspect, because the Flue gas
SM-202 sensing heads look
through the gas flow and do Purge air flows into the duct
kepping the flue gas out
not actually reside in it. The
SM-202 can operate across
flue gas temperatures up to Positive
pressure
1100°C without effect on its duct
readings, providing that the

flue gas is not permitted to
blow back into the purge air Pressurised
section of the head. If the purge air inlet
duct is positive pressure i.e.

is inclined to blow air out of side inlets, then a purge air system of sufficient pressure
must be fitted to the heads in order to prevent the ingress of the hot flue gas to the
head (see right). Also if the flue gas is of greater temperature than 500°C, then a
purge air system should be fitted in any case, to reduce the effect of radiated heat
from the flue gas. If hot gas is allowed to enter the head, even only briefly, then the
sensing head can be destroyed almost instantly.
Duct wall
Radiated heat, particularly from a very hot, un-lagged duct,

can combine with the ambient temperature around the
Heat shield
Heat sensing heads, and cause them to overheat. In this case you
should consider lagging the duct or fitting a heat shield,
which can simply be a metal plate fitted in between the
head body and the heat insulating flange (see left). Heat
Heat
may also be radiated from other nearby heat sources, so
adequate consideration should also be given to them.
Fitting an air purge is a good all round measure which will provide a general cooling
effect to the whole head and protect against radiated and transferred heat both from
the duct wall and from the flue gas.
6
Mounting the sensing heads
The heads must be mounted to 40mm (1 ½”) Class 150 ANSI pipe flanges (see left)
on short extension pipes, opposite each other on the duct. Suitable prefabricated pipe
and flange extensions are
available from DSL, or
40mm Class 150 ANSI flange
you may wish to construct
16mm
your own, however the
4- 16.0 through holes
PCD 98.43mm (3 7/8") extension pipe must be
kept as short as possible.
The pipe and flange
OD 127mm (5")
extension should be
securely welded to a
sturdy section of the duct.
If necessary the duct
ID 40mm (1 1/2")
should be strengthened at
the mounting point to
avoid vibration.
Alignment of the duct mountings for the heads is a very critical aspect of the
installation. If the heads are misaligned the instrument will be less stable, less
accurate and require more frequent maintenance. The SM-202 operating principle
revolves around the concept of throwing a light beam accurately from one side of the
duct to the other, therefore the pipe and flange extensions must be very accurately
aligned so that they are directly
opposite and perfectly angled
towards each other (see right). Straight and true
The SM-202 can only tolerate a

Duct
maximum alignment error of +/- Welded Duct
3°
When the pipe and flange

extensions have been accurately Pipe and flange extension
and securely welded to the duct, for mounting heads to
the heads can be bolted onto the Straight and true
pipe flange extension using M10 or

M12 bolts. Remember to fit any Duct
Welded
heat protecting equipment you may

require at this stage.
7
Installing an air purge system
There are two different types of purge air system for the SM-202, depending on
whether the duct is positive or negative
pressure.
Negative
pressure
Negative pressure: If the site at which you duct
wish to locate the sensing heads draws air

into it naturally and at all times (like most Filter
tall stacks and chimneys), then it is a

Pipe
negative pressure installation. In this case
simply attaching a filter to each of the heads
Clean, dry
with pipes from each of the filters to a clean intake point
dry intake point (see right) will suffice.
Positive pressure: If your head location is

inclined (at any time) to blow or vent out flue
Positive gas, from side ports, then your installation is
pressure
duct positive pressure. In this case you must attach a
clean dry source of air to the purge air
connection of each of the sensing heads. The
air supply should be reasonably high volume
(2scfm), but low pressure - just enough to
Pipe counter the duct pressure and produce a small
air flow towards the duct. Fan blowers are a
common source of air supply for a positive
pressure air purge system, however properly
Filtered fan blower
or clean air supply
filtered (clean and dry) compressed air lines
can also be used.
The air purge connection on the SM-202 head body has a 1/4 BSP internal thread for
making a pipe connection.
Mounting the control unit
The SM-202 control unit is for

nel
mounting in an existing Pa
ment
tru
instrumentation panel, and it is Ins Rubber gasket
therefore assumed that, as a matter of

good practise, the instrumentation
panel is located in an area of
relatively low environmental hazard.
However the SM-202 control unit is
supplied with a rubber gasket, which
SM-202 is inserted into
when properly fitted between the the instrument panel
control unit fascia and the instrument

panel, gives an environmental rating
of IP55 to the front fascia ONLY.
8
The back of the control box does not have an environmental rating as it is assumed
that it will only be exposed to the inside of an instrumentation panel, which must be
environmentally secure.
Ambient temperature around the control unit should ideally be around 25°C, and must
not exceed the range of –20 to +50°C.
The maximum main cable length (from the control unit to the transmitter head) is
100m, and care should be taken that this is a safe and suitable route.
The control unit is designed 193.0

188.5
to be panel mounted, and a 4.5
4.5
suitable cut-out must be 4 - 5.3 dia. holes
made in the instrumentation
panel, as shown to the right
(dims. in mm). This cut-out
100.5
105.0
involves one large

rectangular hole for the
main body of the unit, and
four M5-clear through
holes at the corners to
accept the fixing studs.
Mount the control unit into the instrumentation panel, fixing it in place using the four
M5 nuts supplied.
Running the cable
The cabling route should have been assessed in the survey to establish the position of
the sensing heads and the control unit. Often there will be cable trays in which you
may consider laying the SM-202 cables, but please remember that this unit is a
sensitive electronic measurement device, and that the SM-202 reading may well be
affected if its cables are run alongside heavy power or motor cables which emit
electromagnetic or RF signals.
There are two cables to be run, both of which should be a screened 5-core (minimum)
7/0.22 (0.22mm2) multi-core cable. The first is the main cable from the control unit to
the RX head, and the second is the interconnecting cable from the RX head to the TX
head (around the duct). The main cable should not exceed 100m and the
interconnecting cable should not exceed 25m.
Once the cables have been laid in place they should be fed in through the cable glands
in the sensing heads and the control unit. These glands should then be tightened to
maintain the instruments level of environmental protection. Any unused cable glands
should be sealed off by tightening the gland around some sort of impermeable plug,
for instance a short section of circular section plastic.
Now that the individual components have been physically mounted, the instrument is
ready to be wired up and commissioned.
9
Wiring
All aspects of installation, whether electrical or mechanical, should be carried out

by qualified engineers.
Wiring up the SM-202 can be thought of in 4 stages:
• Power supply wiring

• Control unit to TX wiring (primary interconnecting cable)
• TX to RX wiring (secondary interconnecting cable)
• Ancillary wiring
The following sections describe the best way to tackle these stages, but the diagram
found in Appendix E shows the precise wiring details (including terminal positions
etc.).
Power supply wiring
The SM-202 requires a 5A fused supply voltage of 85-265Vac(RMS) at 50/60Hz.

The supply cable, should be a suitable 3 core (Live / Neutral / Earth) mains cable, and
should be fed into the instrument via one of the cable glands on the back of the
control unit.
Connections should be made directly to the power supply, as shown in Appendix E,

using a suitable connector (Molex 09-91-0300 or equivalent – not supplied).
Control unit to RX wiring (interconnecting cable)
The cable used to connect the control unit to the RX head should be a screened 5-core
(minimum) 7/0.22 (0.22mm2) multi-core cable (available from DynOptic Systems
Ltd if necessary).
A cabling route should already have been assessed when physically mounting the SM-
202 components, so the cable should be run along this predetermined route (ensuring
that the length does not exceed 100m) and fed through a cable gland at both the
control unit, and at the RX head.
Connections as detailed in Appendix E should then be at the terminal marked J3

inside the control unit, and at the terminal marked J1 inside the RX head.
10
RX to TX wiring (main cable)
The cable used to connect the RX head to the TX head should again be a screened 5-
core (minimum) 7/0.22 (0.22mm2) multi-core cable (available from DynOptic
Systems Ltd if necessary).
Again, a cabling route should already have been assessed when physically mounting
the SM-202 components, so the cable should be run along this predetermined route
(ensuring that the length does not exceed 25m) and fed through a cable gland at both
the RX and TX head.
Connections, as detailed in Appendix E, should then be made to the terminals marked

J2 inside the RX head, and J2 inside the TX head.
Ancillary wiring
Having completed the essential wiring necessary for functional operation of the SM-
202, you should consider any ancillary wiring that might be required:
• Alarm relays
• Fault relays
• Analogue outputs
Alarm and fault relay
Both the alarm relay and the fault relay are operated in a fail-safe manner i.e. in a no
alarm situation the alarm
relay is energised, and in an
alarm situation (or in the Fault
N/O N/O relay
event of a power failure) Alarm COM COM
relay
the alarm relay is de- N/C N/C
energised. Therefore, any
warning device to be 1 2 3 4 5 6 J2
connected to either of these

relays should be wired
between the N/C (normally Alarm warning device
closed) and COM (possibly a light)
(common) contacts if they
Fault warning device
are to be activated in an Power source (possibly a light)
alarm or fault situation.
11
Analogue outputs
There are 2 non-isolated analogue outputs

Analogue ground Analogue ground
available, a voltage output (0-10V) and a
4-20mA 4-20mA
current output (4-20mA). Both outputs share
0-10V 0-10V
the same analogue ground terminal position.
1 2 3 1 2 3
J5 J5
Note: The 4-20mA analogue output must
only be connected to a passive input. Some
4-20mA inputs are active, intended to power
a passive transducer - connection to this
0-10V type of input may destroy components on the 4-20mA
SM-202 control unit PCB.
0-10V analogue recording devices can be connected to terminal J5 inside the control
unit (see above left), and 4-20mA analogue recording devices can also be connected
to J5 inside the control unit (see above right).
12
Set-up and commissioning
Please ensure that the instrument has been properly installed in accordance with the
earlier sections of this manual before attempting to power up and commission your
SM-202. It is particularly important that all wiring has been made correctly, that the
heads are securely mounted and well aligned, and that you are able to quickly and
easily isolate the power supply should there be a problem on power-up.
Power-up
When power is first applied to the instrument you should check that all segments of
the LED display, and that both the Alarm and Fault LEDs, briefly illuminate in unison
(for about half of one second), and that immediately following this event the LED
display shows the software version no. (again for approximately half of one second)
before defaulting to normal operation. If nothing lights up, or if the display remains
fully illuminated for more than a few seconds, it is likely that there is a fault or
problem with installation; you should isolate the power to the instrument immediately.
Please note that the Alarm and Fault LEDs may remain continuously illuminated at
this stage, as the set-up process is not yet complete, and that this should not cause
concern.
Assuming that the front panel illuminates properly and the control unit appears to be
working ok, you should then check that the TX head is emitting red light. If this is not
the case, again you should assume a fault or problem with the installation.
Setting the gain
The magnitude of the light signal received by the RX head can vary considerably with
width of the duct and the alignment of the heads, however the measurement circuits
can only process signals within a specific measurable range. Therefore the SM-202
employs a variable amplifier, rather than a fixed amplifier, which can be adjusted for
gain to optimise signal strength within that range, and ensure that the measurement
circuits never reach saturation.
It is ESSENTIAL that the level of gain be properly set for each individual installation
prior to normal operation, and that it is re-set should any aspect of the installation be
changed (e.g. head position etc.). The SM-202 will not function correctly or reliably
unless the gain has been set to a suitable value.
Fortunately, the set gain procedure is highly automated and very easy to accomplish.
The physical installation of all SM-202 components must be complete, including
wiring and the instrument must be operational.
The measurement path, i.e. the light path across the duct and between the two heads
must be clear of smoke, dust, fog, mist, or any other obstructions. The optical surfaces
13
(the window on the TX, and the lens on the RX) must also be clean and free from dirt.
This ensures that the light received at the RX is at its maximum possible level.
The instrument should be switched on and allowed to settle for a few minutes. The
operator should then navigate to select the Gain function on Page 1. The Gain
function displays the current level of gain (the multiplying factor) applied to the light
signal before processing by the measurement circuits. The gain factor can be
anywhere in the range 1.000 to 6707.
The level of gain must be set to achieve the optimum signal strength of 4.0V after
amplification (the signal strength, in volts, can be viewed in the Lite parameter),
across a clear duct, with clean windows etc.
However, it is not necessary for the operator to calculate, and set the level of gain
manually, the SM-202 will perform this duty for you: Having selected the Gain
function, press the Next button, and the displayed gain value will begin to flash. If
you hit Enter whilst the gain value is flashing, the instrument will calculate, and store
(the message “stor” will be displayed briefly) a new gain value optimised for a 4.0V
signal. If whilst the gain value is flashing, you press the Cycle button, the instrument
will move to the next parameter on the page, leaving the gain factor unchanged.
Remember that if the location or fixing of the heads is changed in any way, the gain
should be re-set in this manner.
Choosing the unit of measurement
The SM-202 can display opacity in a number of different unit scales. Select the
desired unit of measurement from the Unit function on Page 1:
Opacity (100x(1-T)) range: 0.000 to 100.0%
Transmission (T) range: 1.000 to 0.000T
Extinction (Ln(1/T)) range: 0.000 to 3.000 (typ.)
Extinction (log10(1/T)) range: 0.000 to 3.000 (typ.)
Ringelmann (5*(1-T)) range: 0.00-5.00)
14
The Adjust function
Most opacity monitors have a span control to set the sensitivity, and zero control
(light level offset) to adjust for background lighting interference.
The SM-202 however uses modulated LED technology, which makes it immune to
background light interference, and therefore immune to zero drift (by virtue of the fact
that absolute zero is fixed as the point of complete obscuration of the modulated light
only, from the photocell in the RX head i.e. no modulated light at the receiver = 100%
opacity on the display). Therefore only an internal span control is required to scale the
reading and calibrate the instrument.
To make this adjustment as simple as possible we have introduced the Adjust

function. The Adjust function manipulates the internal span value to force the
instruments reading to any value (within range) entered by the operator. In practise
this means that for readings in Opacity, Extinction, and Ringleman, we can use the
Adjust function to set the 0.000 reading, and that for transmission we can set the
1.000 reading; effectively calibrating the instrument.
This adjustment should be performed under the same conditions as were attained
during the setting of the gain i.e. the path between the two heads should, and the
optical surfaces of both heads, should be clear, unobstructed, and free from smoke,
dust, mist, or fog. It should also be noted that the SM-202 does have a “warm up”
period when it is first switched on, and that the instrument should be left to settle for
approximately 10 minutes after power-up before using the Adjust function.
When these conditions have been met, select the Adjust feature from Page 0 and enter
the desired reading: 0.000 for Opacity, Extinction, and Ringleman; and 1.000 for
Extinction, remembering to press the Enter button to store the value. At this point the
instrument will leave the Adjust function and move back to display the measurement
reading (which should now be reading the value just entered).
Where it is not possible to achieve a clear light path for calibration 0% opacity; it is
possible to use the Adjust feature to set a positive opacity reading (where that reading
is known or can be measured/calculated independently). Every effort should be made
to use this feature to set a reading as close to 0% opacity (1.000 for Extinction) as
possible.
The Adjust feature can also be used in a similar way to calibrate for other linear scales
of measurement, for instance mg/m3. Only in this case you would Adjust the reading
to match an independently verified (i.e. iso-kinetic sampling) loading passing through
the light path of the instrument.
Damping
Opacity levels in a moving stream of air are very dynamic, and the SM-202 is more
than capable of tracking these rapid fluctuations real time. However this is not usually
a desirable scenario, as most users wish to see an average opacity, so that they can
track the underlying trends in the duct opacity.
15
To achieve this average the SM-202 employs a damping function, which can be set
anywhere from 0 to 999.9 seconds using the Damp parameter on Page 0.
Alarm level
As you would expect, it is possible to set an alarm level, at above which the alarm
relay will de-activate (see the section on Wiring for details of connections), and the
corresponding LED on the front panel will illuminate. To set this alarm level, select
the Alarm parameter Page 0 and enter the measurement reading at which the alarm
should operate.
Analogue out put
There is a non-isolated analogue output available on the SM-202, which reports in

both 0 to 10V and 4 to 20mA scale (see the section on Wiring for details). You can
scale this output (both the top and the bottom) using the AnHi and AnLo parameters
on Page 0. When the instrument reading equals the value set in AnHi, the analogue
output will go full scale (10V or 20mA), when the instrument reading equals the value
set in AnLo it will go bottom scale (0V or 4mA), and when it’s reaponse inbetween
AnHi and AnLo will be linear.
16
Routine checks and maintenance
The SM-202 needs very little maintenance, and on the whole common sense should
dictate a maintenance schedule.
Lenses
The most important element in maintaining the instrument is to keep the lenses of
both the TX and RX head clean, as deposits on the optics will reduce the strength of
the light signal, and cause an increased opacity reading.
To clean the lenses, release the catches on either side of the heads, remove the head
box, and gently brush, or blast the dirt off with a clean airline. If the soiling is so bad
that this does not remove the dirt, gently wipe the lens clean with a damp cloth and
then dry with a lint free cloth.
Remember to replace the rubber gasket when clipping the head boxes back onto the
metal head bodies.
The frequency with which this type of maintenance needs to be performed is entirely
dependant on factors unique to each installation. Factors such as the level of
smoke/particulate in the stream gas, and the inclusion, or not, of an air purge system
will all effect the rate at which the optics dirty. However as an initial guide, we
recommend that you start by cleaning the optics once a week and assess the rate at
which dirt is deposited. If the lenses are always very dirty, then you should increase
the frequency, and vice versa.
Transmitter LED
LEDs have an extremely long life in comparison to an ordinary filament bulb light
source, however over long periods of time they do degrade, and it is important to
monitor the performance of the LED in the TX head for degradation. If the strength of
light output from the LED falls it may become too weak to throw its beam across the
duct.
The Ref feature on Page 1 displays the voltage generated by a photocell located
alongside the main LED in the TX head. If this voltage should fall below 1.5V the
LED should be replaced. We recommend that the Ref voltage is checked once a year.
17
Fault finding
The SM-202 is a very reliable instrument, and provided that it is installed,
commissioned, and maintained correctly there is no reason why it should not enjoy a
long and trouble free life. However, circumstances conspire to ensure that some
machines do fail from time to time, and therefore we have included some information
on basic fault finding which should help operators investigate and isolate the cause of
common failures quickly and effectively.
Fault messages
As well as lighting the fault indicator LED on the front panel and activating the fault
relay, a fault condition recognised by the instrument will cause the SM-202 to flash
up one of the following fault messages (in the measurement reading window only):
Hi S – is an abbreviation of High Signal, indicating that he control

unit is getting too much signal from the receiver head. The gain
setting procedure should be repeated to reduce the level of gain
applied by the RX head (see the section on Set-up and commissioning).
Lo C – is an abbreviation of Low Compensation, indicating that the

control unit is receiving a weak signal from the compensation
photocell strapped to the side of the TX source.
This indicates that the LED source is either too dim or is not producing any light at
all. This may be a result of degradation of the TX LED (see the section on Routine
checks and maintenance) in which case a replacement TX board may be required.
Alternatively the LED may not be producing any light at all, in which case the fault
may lie with either a failed LED, or incorrect wiring between the control unit and the
TX head.
Hi C – is an abbreviation of High Compensation, indicating that the

instrument is reading in excess of 4.95V from the compensation
photocell strapped to the side of the LED light source in the TX
head. This indicates that the TX light output has increased (extremely unlikely) and
that the measurement circuits are in danger of becoming saturated, which would of
course prevent the instrument from making compensations for fluctuations in the light
output of the LED. It would be unusual to see an increase in the light output of an
LED unless it was submitted to extreme cold conditions. Investigate the TX head.
Head – indicates that the control unit has lost communications with
the RX head. This could be as a result of faulty, damaged, or
incorrect wiring, or it could be as a result of a fault in the electronics,
either in the CPU, or in the either of the two sensing heads.
18
Appendix A – Operator interface familiarity
The SM-202 operator interface (front panel), from where the operator can monitor
and control the instrument, has been designed to be clear and intuitive to use, so that
the operator can quickly and easily get to grips with day to day operation. It consists
of a single 4-digit LED display, four pushbuttons, and two warning lights (LEDs).
The LED display can be thought of as a window, or viewing port, used to view
various settings, parameters, and readings stored in a row (like in a spreadsheet)
which we call a Page. By using the Cycle button, the operator can step from each
parameter to the next, looping round all the various different parameters on the Page
continuously.
All functions and parameters consist of both a name e.g. Read, and a value e.g. 1.574.
As you step through the various functions and parameters, the display will show first,
the name of the parameter, and then after a one second pause, the value of the
parameter.
The Cycle button cycles you through the various parameters available on the Page.
The Next button, when first pressed, initiates change to the parameter shown in the
display (where change is applicable) by highlighting the first digit (a highlighted digit
flashes). The highlighted digit can then be changed using the Increase button. When
the Next button is pressed for a second time, the next digit adjacent will be
highlighted for change and so on, until you reach the far right digit in the display, at
which point pressing the Next button will loop back to highlight the first digit once
more. Please note that where the decimal point is used, this also will be highlighted
for change when using this button.
The Increase button is used to increase the value of a digit when it has been
highlighted for change using the Next button. It will also move the decimal point
when it has been highlighted.
The Enter button is used to acknowledge completion of a data entry, after which
“Stor” will be flashed in the display to confirm the action.
The Alarm LED will illuminate when the particulate reading exceeds the alarm level
set in the instrument. The alarm relay will also de-energise at the same time.
The Fault LED will illuminate when the instrument flags a fault condition. The fault
relay will also de-energise.
Please note that some parameters are subject to range restrictions, and if the operator
attempts to enter a value outside that range, or any other invalid data, the instrument
will reject that entry, and flash “ERR” briefly to confirm the fact.
19
Appendix B – Pages (the operating system)
The SM-202 has two Pages in the display:
• Page 0 – used for normal day-to-day monitoring and control of the instrument.
• Page 1 – used exclusively during set-up, commissioning, and maintenance.
Only one page will be displayed at any one time.
Switching between pages
Select the Page function in the display, press the Next button to start the Page no.
flashing, then use the Increase button to select the desired Page no. and then press
Enter to select it.
Page 1 is password protected, so when you select Page 1 you will be prompted for a
password (any 4 digit no.). If you enter the correct password and press Enter, the
instrument will confirm the action with “Yes” and display Page 1. If you enter an
incorrect password, the display will briefly read ”no” and then default back to the read
parameter on Page 0.
Please note that if the instrument is left in Page 1 for more than 5 minutes with no key
activity, the SM-202 will drop back to the Read function on Page 0 by default, and the
password will have to be re-entered in order to regain access to Page 1.
Page 0
After installation and commissioning the instrument should be normally left on Page 1
for day-to-day use. Here the operator can view the instruments reading as well as
view and alter most of its operational settings. Most instruments will be left on this
Page for the vast majority of their operational life.
Page 0 parameters
Read – displays the current instrument reading in the unit selected

(see Unit on Page 1). The instrument will revert back to this
parameter after 5 minutes of inactivity. Range 0.000 to 9999.
Page – displays the current Page and allows you to change to

another Page. Range: 0 to 1.
Adjust – forces the current instrument reading to match the value

entered here, by adjusting the internal instrument span. This
function can be used to perform a sort of calibration in that here the
20
operator can insert an independently verified measurement (i.e. from iso-kinetic

sampling or something) and instantaneously force the instrument reading to match
this figure. Range 0.000 to 100.0.
Damp - displays and allows you to adjust the damping applied to

the instruments reading in seconds. Here you can introduce a
damping element to the electronics to smooth out the reading. The
damping effect introduced here not only affects the reading in the display, but also the
analogue outputs, the serial output, and the alarm relay. It is recommend that you set a
minimum Damp figure of 30.00 seconds. Range 0.000 to 9999 seconds.
Alarm - displays and allows you to adjust the reading level above
which the alarm relay and LED are activated. Please note that the
relay is energised in the no alarm state and de-energised in the
active alarm state (fail-safe). Range 0.000 to 999.0.
AnLo - displays and allows you to adjust the low end of the
analogue output scale. Here you can set the reading level at which
the analogue output reaches bottom of scale e.g. 4mA or 0V. It is
usual practice to set this to zero. Range -999 to 9999. Please note that this value
cannot be set in excess of the value set in AnHi.
AnHi - displays and allows you to adjust the high end of the
analogue output scale. Here you can set the reading level at which
the analogue output will reach full scale e.g. 20mA or 10V. It is
usual practice to set this parameter to twice the ALARM level, so that instances where
the alarm level has been exceeded can be analysed properly. Range 0.000 to 9999.
Please note that this value cannot be set lower than the value set in AnLo.
The 4-20mA analogue output must only be connected to an isolated passive input.
Some equipment have active 4-20mA inputs, intended to power a passive transducer
- connection to this type of input may destroy components on the SM-202 control
unit PCB.
Page 1
Page 1 contains features that are strictly for set-up and commissioning, or
maintenance diagnostics only. Only qualified personnel with a thorough
understanding of the instrument should attempt to use the functions here, as improper
use could have serious effect on the operation of the instrument. This page is
password protected.
21
Page 1 parameters
Lite – (or Light) is a diagnostic figure only, showing the magnitude

of the light signal (in Volts) after amplification. This value will have
been determined to approximately 4.00V when the gain was set (see
the section on Set-up and commissioning), but will reduce in a direct proportion to the
level of opacity, i.e. 2.00V will equal apprx. 50% opacity and 0.00V will equal 100%
opacity.
If the light signal exceeds 4.95V the measurement circuits in the SM-202 will be close
to saturation and the instrument will declare a fault condition known as HiS, or High
Signal (see the section on Fault Finding). Range 0.00 to 4.95V
Ref – is an abbreviation of reference voltage, and displays the

voltage measured by a photocell attached to the side of the LED
light source in the TX head. This reference voltage is used to
monitor any changes in light output, and to calculate any necessary compensation of
the instrument reading due to those changes.
If this voltage exceeds 4.95V the instrument will declare a fault condition known as
HiC, or High Compensation (see the section on Fault Finding).
If this voltage falls below 0.5V, the LED is considered to be too weak for normal
operation and the instrument will declare a fault condition known as LoC or Low
Compensation (see the section on Fault Finding). Range 0.00 to 4.95V.
Gain - here you can view the current amplification gain factor, and
if necessary re-set it as described in “Set-up and commissioning”.
Range 1.000 to 6707.
Unit – displays, and allows the operator to change the unit of

measurement displayed by the SM-202.
Page – displays the current Page and allows you to change to

another Page. Range 0 to 1.
Pass – displays the current password, and allows you to change it

to something more memorable. Remember to make a careful note
of your chosen password, as this is the only Page on which the
password can be viewed and changed, and this Page is password protected. Next time
you are prompted for your password it will be the password entered here that you will
have to use. The default is 0000. Range: -999 to 9999.
22
Erase – is a special feature which allows the customer to erase the

instruments EEPROM memory and reset all the standard factory
settings, with exception of the password. This is a very powerful
and potentially hazardous tool that should only be used in extreme circumstances.
In order to clear the EEPROM, select this parameter, press the Next button to
highlight the Eras text, then use the Increase button to toggle to“Yes”, and hit Enter.
The instrument will then display “CLr” briefly and reset EEPROM, defaulting back to
Page 0.
Warning: clearing the instruments EEPROM will overwrite ALL settings previously
programmed by the operator (with the exception of the Gain factor) and the
instrument will need to be set up again from scratch. It is recommended that any
important settings or parameters are carefully taken down prior to performing this
operation.
Appendix C - Recommended spares
These instruments are often employed on environmentally sensitive (and therefore

strictly regulated), continuous processes, where down time is very unfavourable, and
it is vital that spare parts are carried to enable fast turn around repairs.
In our experience, faults usually stem from misconnection, power supply surges, or
lightning strike (particularly on tall stacks). We therefore recommend that operators
hold spare TX, RX and PSU(inside the control unit) boards. These are the parts most
often requested as spares, or found to be damaged on return. Part nos. as follows:
1off TX board: Z-PC203A-SM
1 off RX board: Z-A1165-XX
1 off PSU board: PSU-003
23
Appendix D - Principle of operation
The measurement system uses an LED light source to transmit a visible, RED, light
beam from the transmitter head to the receiver head. As the light path is increasingly
obscured, less light falls on the receiver. In order to compensate for small variations in
the transmitted light amplitude, due to the effects of temperature and ageing, a
compensation photocell is fitted in the transmitter head. A microprocessor uses these
two signals to determine the opacity value. The other displayed units (transmission
etc.) are all related to opacity and are calculated by the microprocessor.
To allow for the effects of different path lengths (the light received becomes weaker
over longer path lengths) the receiver has a variable sensitivity amplifier controlled by
the microprocessor. The apparent light level can thus be fixed for a wide range of
light path lengths.
To avoid problems with ambient light upsetting the photocell, the light source is
modulated (switched on and off) at a frequency of approximately 1.5KHz. The
electronics responds only to light which is at this frequency and rejects other light.
The glass window (transmitter side) and lens (receiver side) are prevented from
becoming contaminated by a purge air flow. The air is directed at the window/lens
and then turns around and vents into the duct to which the heads are attached. In some
circumstances where there is a negative pressure in the duct it may be possible to use
this to draw in the purge air from the outside ambient air. In most cases, however, a
fan blower will be required to be connected to the heads to provide this purge air.
24
Appendix E – Wiring details
Internal DC J3
BLU
connector RS485B
GRN
PSU PCB RS485A
SCRN
GND
SCRN
GND
RED
VN BRN
VP 1
LIVE
NEUTRAL J2
SERIAL
J4 COMMS.
CONNECTOR
EARTH
J5
1 1
Internal DC
connector CPU PCB
Control Unit
Main cable
85 to 265VAC 50/60Hz Mains power cable

5A fused power input J1
BRN
RED 1 VP
SCRN VN
SCRN GND
GRN GND
BLU RS485A
RS485B
RX PCB
J2
Interconnecting cable
SCRN 1
LED-
RED LED+
ORA COMP
SCRN GND
GRN VP
BLU VN
J3 Receiver
1
BLU
VN GRN
TX VP SCRN
GND ORA
COMP RED
LED+ SCRN
LED-
1
Installation Wiring
Transmitter
25

sm-202 Manual V1.01

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SM-202 Continuous Opacity Monitor Manual V1

Installation must be completed by qualified personnel, in accordance with this

All aspects of installation, whether electrical or mechanical, should be carried out

Locating the sensing heads

Airflow: Airflow is a major

pattern of airflow can cause

4 duct widths 4 duct widths

upstream of the heads. TX RX Gas flow

Deviations can be caused by

outlets, intrusions to the gas Gas flow

flow, or extraction points for Duct

The heads should never be

horizontal stretch of duct, as Fan

particulate will fall into the

under the force of gravity.

Rain and condensing steam: These elements

Cable lengths: The cable length

power cables or switch gear !

cabling. Tight bends, pinching,

Assessing temperature protection

The first aspect to be considered is the external

Flue gas temperature is not a

readings, providing that the

duct is positive pressure i.e.

Radiated heat, particularly from a very hot, un-lagged duct,

Mounting the sensing heads

The pipe and flange

The SM-202 can only tolerate a

When the pipe and flange

the heads can be bolted onto the Straight and true

pipe flange extension using M10 or

heat protecting equipment you may

Installing an air purge system

wish to locate the sensing heads draws air

tall stacks and chimneys), then it is a

dry intake point (see right) will suffice.

Positive pressure: If your head location is

Mounting the control unit

The SM-202 control unit is for

therefore assumed that, as a matter of

control unit fascia and the instrument

The control unit is designed 193.0

involves one large

Running the cable

All aspects of installation, whether electrical or mechanical, should be carried out

Wiring up the SM-202 can be thought of in 4 stages:

• Power supply wiring

Power supply wiring

The SM-202 requires a 5A fused supply voltage of 85-265Vac(RMS) at 50/60Hz.

Connections should be made directly to the power supply, as shown in Appendix E,

Control unit to RX wiring (interconnecting cable)

Connections as detailed in Appendix E should then be at the terminal marked J3

RX to TX wiring (main cable)

Connections, as detailed in Appendix E, should then be made to the terminals marked

Alarm and fault relay

connected to either of these

There are 2 non-isolated analogue outputs

Set-up and commissioning

Setting the gain

Choosing the unit of measurement

Opacity (100x(1-T)) range: 0.000 to 100.0%

Transmission (T) range: 1.000 to 0.000T