Dust concentration detectorIt is the core equipment for dust exceeding warning, explosion prevention and dust prevention in industrial sites. The rationality of installation location and the accuracy of debugging parameters directly determine the monitoring effect. The following is a step-by-step installation process and debugging points, simple and easy to operate.

1、 Preparation work before installation

1. Confirmation of installation conditions

2. Preparation of tools and materials

Installation tools: impact drill, screwdriver, wrench, level, tape measure

Auxiliary materials: expansion bolts, cable conduit, sealant, insulation tape

2、 Core installation steps (checklist execution)

1. Selection of installation location (key steps)

Installation near dust source: The probe should be directly facing the dust generation point (such as belt transfer port, crusher discharge port), 1-3 meters away from the dust source, and at a height level with the dust diffusion height (generally 2-4 meters above the ground).

Avoid ineffective areas: Avoid air vents, wall corners, and equipment obstructions to prevent monitoring errors caused by airflow disturbances or uneven dust accumulation.

Multi point layout principle: Large area workshops are arranged at a density of 50-100 square meters per unit; Install one long-distance belt corridor every 50 meters.

Explosion proof area requirements: Explosion proof detectors must be installed in an explosion-proof manner, with cables laid in explosion-proof conduit and joints sealed with explosion-proof seals.

2. Detector fixation and wiring

Bracket installation: Use expansion bolts to fix the bracket to the wall or column, calibrate with a level to ensure that the bracket is level and stable.

Host fixing: Mount the detector host on the bracket, tighten the fixing screws, and ensure reliable grounding of the host shell (grounding resistance ≤ 4 Ω).

Probe installation:

Pipeline probe: Insert into the air duct/flue, probe deeply into the interior of the pipeline with a diameter of 1/3~1/2, perpendicular to the direction of airflow, and seal the opening of the pipeline to prevent air leakage.

Diffuse probe: installed in the monitoring area, with the probe facing downwards (to prevent rainwater and dust from directly entering), at a distance of ≥ 30cm from obstacles.

Cable connection:

Power cord: Connect the corresponding voltage (usually DC24V or AC220V) according to the equipment nameplate, distinguish the positive and negative poles/neutral wires, and avoid reversing and burning the equipment.

Signal line: Connect the detector to the central control system (such as PLC, DCS) using shielded cables, with the shielding layer grounded at one end to reduce signal interference.

3. Check after installation

Check whether the connection between the host and the probe is firm, whether the cable is fixed in place, and whether there is any looseness or sagging phenomenon.

Seal the cable openings with sealant to prevent dust and rainwater from entering the interior of the equipment.

Confirm that the grounding circuit is unobstructed and that the explosion-proof components are not damaged.

3、 Debugging operation process

1. Check before powering on

Recheck whether the voltage of the power line and the wiring method of the signal line are correct.

Check the appearance of the equipment for any damage, and ensure that the probe filter is clean and unobstructed.

2. Power on and parameter initialization

Connect the power supply, the detector will perform a self-test (with the indicator light flashing for about 3-5 minutes), and enter standby mode after the self-test is completed.

Enter the parameter setting interface through the detector button or the upper computer software to initialize the basic parameters:

Range setting: Set according to the type of dust on site (such as coal dust range 0~1000mg/m ³, metal dust range 0~500mg/m ³).

Unit switching: Select units such as mg/m ³ and ppm as needed.

Address setting: When multiple detectors are networked, set different device addresses to avoid conflicts.

3. Calibration operation (ensuring monitoring accuracy)

Zero point calibration: Place the probe in clean air, enter the calibration interface, perform "zero point calibration", and wait for the calibration to be completed (the screen displays stable zero point).

Calibration of calibration points:

Using a standard dust calibrator, introduce known concentrations of dust gas into the probe detection area.

Enter the standard concentration value in the detector, perform "calibration point calibration", and save the calibration parameters.

After calibration, repeat the test 2-3 times to ensure that the indication error is ≤ ± 5% (in accordance with national standards).

4. Alarm threshold setting

Set two-level alarm thresholds according to on-site safety standards:

Warning threshold: Set to 80% of the alarm threshold (e.g. alarm value of 100mg/m ³, warning value of 80mg/m ³), to remind dust removal in advance.

Alarm threshold: Referring to national standards (such as the maximum allowable concentration of coal dust in the workshop of 4mg/m ³), combined with the actual setting on site.

Set up alarm linkage actions, such as triggering sound and light alarms when exceeding standards, starting dust removal equipment, and shutting down dust producing equipment.

5. Data validation and linkage testing

On site slight disturbance of dust, observe whether the detector values are sensitive and consistent with the actual dust concentration trend.

Simulate the scenario of exceeding the standard, test whether the sound and light alarm is triggered, and whether the linked equipment responds normally.

Check if the central control system can receive real-time concentration data and alarm signals from detectors.

4、 Installation and debugging precautions

Installation and commissioning personnel must hold certificates before taking up their posts, and operations in explosion-proof areas must comply with hot work regulations. It is strictly prohibited to open covers with electricity.

The probe filter needs to be cleaned regularly (the first cleaning cycle after installation is 1 week) to prevent dust blockage from affecting sampling.

Calibration requires the use of the same type of standard dust, with different dust having different scattering characteristics, to avoid errors caused by cross type calibration.

After debugging is completed, fill in the installation and debugging records, retain calibration data, and file for future reference.