Emerson IM-105-4000 User Manual
Instruction Manual
IM-105-4000, Orignal Issue
August 2005
OPM 4000
Opacity/Dust Density Monitor
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Instruction Manual
IM-105-4000, Original Issue
August 2005
OPM 4000 Opacity/Dust Density Monitor
OPM 4000
ESSENTIAL
INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Rosemount Analytical designs, manufactures and tests its products to meet
many national and international standards. Because these instruments are
sophisticated technical products, you MUST properly install, use, and
maintain them
specifications. The following instructions MUST be adhered to
into your safety program when installing, using, and maintaining Rosemount
Analytical products. Failure to follow the proper instructions may cause any
one of the following situations to occur: Loss of life; personal injury; property
damage; damage to this instrument; and warranty invalidation.
• Read all instructions
product.
• If you do not understand any of the instructions, contact your
Rosemount Analytical representative
• Follow all warnings, cautions, and instructions
supplied with the product.
• Inform and educate your personnel in the proper installation,
operation, and maintenance of the product
• Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes. Connect all products to the proper electrical and
pressure sources.
• To ensure proper performance, use qualified personnel
operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use
replacement parts specified by Rosemount. Unauthorized parts and
procedures can affect the product's performance, place the safe
operation of your process at risk, and VOID YOUR WARRANTY
Look-alike substitutions may result in fire, electrical hazards, or
improper operation.
• Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.
to ensure they continue to operate within their normal
and integrated
prior to installing, operating, and servicing the
for clarification.
marked on and
.
to install,
.
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The information contained in this document is subject to change without
notice.
OPM 4000
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
Instruction Manual
IM-105-4000, Original Issue
August 2005
PREFACE
DEFINITIONS
The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the OPM 4000.
Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual completely.
The following definitions apply to WARNINGS, CAUTIONS, and NOTES
found throughout this publication.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
NOTE
Highlights an essential operating procedure, condition, or statement.
SYMBOLS
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number, and is not related to the
illustration in any technical manner.
ii
Instruction Manual
IM-105-4000, Original Issue
August 2005
OPM 4000
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1
Description and
Specifications
SECTION 2
Installation
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transmissometer/Retro Reflector. . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Optional Air Purge Weather Cover System . . . . . . . . . . . . . . . . . . 1-1
Alignment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Normal Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Internal Calibration System, Zero Mode. . . . . . . . . . . . . . . . . . . . . 1-2
Internal Calibration System, Span Mode . . . . . . . . . . . . . . . . . . . . 1-2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Choose an Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Stack Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drawing Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Alignment of Stack Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Installation of Stack Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Sample Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Mounting the Air Plenum and Weather Covers . . . . . . . . . . . . . . . . . . 2-4
Transceiver and Retro Reflector Assembly . . . . . . . . . . . . . . . . . . 2-5
Beam Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Air Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SECTION 3
Startup and Calibration
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Before Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Stack Exit Correlation Computation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Startup Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Verifying Instrument Operation and Configuration. . . . . . . . . . . . . . . . 3-2
Edit Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Factory OPLR Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Quick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Zero/Span Calibration Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
OPM 4000
Instruction Manual
IM-105-4000, Original Issue
August 2005
SECTION 4
Operation
SECTION 5
Zero and Span
Calibration
SECTION 6
On Line Zero Reflector
Option
OPM 4000 Operations and Adjustments . . . . . . . . . . . . . . . . . . . . . . . 4-1
Front Panel LED's. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Unit Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Alarm Set Point Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Alarm Time Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-20 mA Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Recorder or Other Device Calibration . . . . . . . . . . . . . . . . . . . . . . 4-3
Auto Cal Timer Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Remote Calibration Cycle Initate . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Remote Calibration Cycle Acknowledgment . . . . . . . . . . . . . . . . . 4-4
Service Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Clear on Stack Zero and Span Calibration . . . . . . . . . . . . . . . . . . . . . 5-1
Zero Reflector Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Span Filter Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Record the Zero/Span Values in the Quick Menu . . . . . . . . . . . . . . . . 5-4
Off Stack Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Using the On Line Zero Reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Filter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Course Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Micro-turn Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Filter Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SECTION 7
Maintenance
SECTION 8
Troubleshooting
SECTION 9
Replacement Parts
SECTION 10
Drawings
APPENDIX A
Safety Data
Preventive / Corrective Maintenance Schedule. . . . . . . . . . . . . . . . . . 7-1
Control Unit Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Mounting: Under 6 ft (1,8 m) Diameter . . . . . . . . . . . . . . . . . . . . . . . 10-2
Mounting: Over 6 ft (1,8 m) Diameter . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Air Purge/Weather Cover Mechanical Installation . . . . . . . . . . . . . . . 10-4
Panel Cutout for Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Control Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Control Unit Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Typical System Wiring (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Typical System Wiring (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Transceiver and Retro Reflector Signal and Control Wiring . . . . . . 10-10
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
TOC-2
Instruction Manual
IM-105-4000, Original Issue
August 2005
OPM 4000
Section 1 Description and Specifications
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-4
SYSTEM OVERVIEW
T ransmissometer/Retro
Reflector
Control Unit
Optional Air Purge
Weather Cover System
The OPM 4000 Opacity/Dust Density Monitor provides continuous, low
maintenance, precision measurement of opacity and optical density in
industrial applications. It is a cost-effective instrument that serves as an aid in
operating pollution and/or process control equipment.
The OPM 4000 is a precision, double-pass, dual beam transmissometer that
consists of a transceiver (transmitter/receiver) mounted on one side of a stack
or duct and a passive reflector mounted on the opposite side. The light
source, photo detectors, and all measurement/reference optics used in
opacity measurement are housed in the transceiver.
The function of the reflector is to return the measurement beam to the
detector in the transceiver, creating a double pass across the process stream.
The standard reflector is used for measurement path lengths up to 15 feet
(4,6 m). For longer path lengths, maximum 60 feet (18,3 m), reflectors, optical
parts and electronics will vary.
Mounted in a control room environment, the OPM 4000 control unit provides
instrument control functions, opacity readings, alarms and fault indicators,
analog outputs, and diagno stic s with co ntac t clo su res.
The transceiver and reflector may be mounted in weather covers. The
weather covers are fairly compact to allow movement around them even on a
three-foot walkway or platform. They protect the stack-mounted components
from dirt, moisture, stack temperatu res with in the sp eci fi ed ambient
temperature limits, and errant air currents around the stack.
Alignment System
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The air purge system constantly circulates air past the optical window. The
airflow is directed through the hose to an air plenum on the stack side of the
optical window. The airflow in the air plenum area results in reduced pressure
and increased velocity. This venturi effect tends to continually draw the air
around the optical window into the purge air stream, thereby keeping the lens
clean for long periods.
The OPM 4000 includes a built-in through-the-lens alignment system. The
alignment target can be viewed through a window on the transceiver.
Adjustments to changes in alignment are provided by a 3-point alignment
system, which is integral to the air plenum.
OPM 4000
Instruction Manual
IM-105-4000, Original Issue
August 2005
Cabling
PRINCIPLE OF
OPERATION
Normal Mode of
Operation
The standard cabling used between the stack-mounted units and the control
unit is at a minimum 6-pair, #20 AWG, twisted, shielded cable. More pairs or
larger than 20 AWG is acceptable.
The dual beam measurement system has a stack mounted transmissometer
sensor system that consists of an optical transceiver mounted on one side of
the stack and a retro reflector mounted on the other (Figure 1-1). To avoid
errors due to ambient light, the lamp is electronically modulated and projects
a collimated beam of light, which is split into a reference beam, and a
measurement beam by an optical beam splitter. The reference beam is
directed to the reference detector (RD). The measurement beam is projected
across the stack to a retro reflector that returns the beam back across the
stack to a beam splitter and directs the measurement beam to the
measurement detector (MD). A portion of the returning light is also sent to the
TTL (Thru The Lens) bulls-eye target viewed through a window provided at
the rear of the transmissometer. The bulls-eye is used to correct changes in
alignment and is unique in that no moving parts are used.
The ratio of the measurement and reference detectors is used to provide a
transmittance
detectors, and a measurement / reference ratio is used throughout for the
calculations, the monitor is insensitive to variations in light intensity. Since all
measurements are made on a ratio basis, all resulting computations are
independent of the absolute intensity of the light source or contamination of
the optics associated with the collection and focusing of the energy from the
lamp. The (T
unit for processing. At the control unit the signal is processed to read 0-100%
opacity, and provide alarms and outputs.
2
(T2) signal. Because the same light source is used for both
2
) signal is converted to a current format and sent to the control
Internal Calibration
System, Zero Mode
Internal Calibration
System, Span Mode
1-2
Zero and span calibration checks can be initiated manually, automatically, or
by a PLC or computer. During the zero calibration mode a calibrated zero
reflector is placed in front of the transceiver optical package testing all optical
surfaces and electronic components to assure zero point has not changed.
In the span mode a Span filter of known neutral density is placed in the
measurement path and produces a specific up scale reading in accordance
with the latest EPA requirements. The zero and span cycle provides a
continuous check of all the optical components and surfaces, the main lamp,
the detector, interconnecting wiring, control unit, and computation analysis.
Instruction Manual
IM-105-4000, Original Issue
August 2005
Figure 1-1. Component
Relationships
TTL Bulls-Eye
OPM 4000
TRANSCEIVER WITH AUTO ZERO SPAN CAPABILITY
Aperture P
Main Lamp
Span Filter out:
Span Filter in:
Zero Reflector out:
Zero Reflector in:
Projection Lens
Span Filter
RD MD
Retro Reflector
Zero Reflector
Aperture V
1-3
OPM 4000
SPECIFICATIONS
Instruction Manual
IM-105-4000, Original Issue
August 2005
OPM 4000 Specifications
Design and performanc e Meets or exceeds PS-1 revised and ASTM D6216-98
Peak and Mean Spectral
Response
Relative Spectral Response <10%
Angle of View < 4.0o from optical axis
Angle of Projection < 4.0o from optical axis
Calibration Error/Accuracy ±1% of full scale
Response Time <10 seconds
Zero Drift <0.5%
Calibration Drift <0.5%
Operational Period In excess of PS-1 required 336 hrs
Zero/Span Calibration Manual or automatic with zero mirror and neutral density
Remote control unit
Numeric Digital Display 5/8 in.
(15,9 mm), 4-digit LED
Display Resolution 0.1% Opacity
Alphanumeric 8 character
LED (0.2 in.) Fault Display
Bargraph Left/Right: 51 segments LED 5.1 in. (129,5 mm) for
Operator Indicating LED’s Run, Alarm, Operate, Cal in progress
High Opacity Set Point 0-100% of full scale
High Opacity Delay Adjustable 0-300 seconds
High Opacity Alarm Reset Automatic
Open Transistor Collector
Outputs
Dry Contacts Two selectable (option: two additional)
Instantaneous Opacity and
Average Outputs
OPLR (Exit Correlation Lx /
2*Lt)
Cal Cycle initiate Local, remote and timed adjustable 1 to 24 hours
Enclosure NEMA 13, IP65, Height: 7.38 in. (187,5 mm) x Width: 3.00
Ambient Temperature Range 32o to 122oF (0o to 50oC)
Power Requirements 120 VAC (±15%), 50/60 Hz, 22VA
Network Protocol: Modbus (ASCII or RTU mode), type RS-485,
Configuration Speed: 300-38,400 baud, type RS-232
Transceiver Service module
Display 5/8 inch (15,9 mm), 4-digit LED, selectable for % opacity
Local Zero/Span Manual on demand
Test Jacks Transceiver to remote control current loop
Diagnostics Loss of power, current loop open, maintenance mode
Photopic; 515 to 585 nm, less than 10% of peak response
outside 400 to 700 nm
filter
Selectable for instantaneous opacity, average opacity.
optional mg/m
Air purge low, No Stack Power, T2 4-20 Lost/low,
Maintenance Mode, Window Dust, Zero Cal Fail, Span Cal
Fail, Manual Cal.
instant/average opacity. 20 segment LED 2.1 in. (53,3 mm)
for window dust and drift in % opacity.
Four selectable
4-20 mA grounded reference, 800 ohms max. (two
additional optional)
0.2 to 3.0
in. (76,2 mm) x Depth: 7.75 in. (196,9 mm), Weight 6 lbs
(2,24 kg)
optically isolated
and % transmittance
3
1-4
Instruction Manual
IM-105-4000, Original Issue
August 2005
OPM 4000
OPM 4000 Specifications
Transceiver/Reflector
Enclosure NEMA 4 watertight enclosure
Path Length 2 to 15 ft (0,6 to 4,6 m). Longer available
Optical System Double pass
Light Source Aging
Compensation
Light Source Life > 5 years
Ambient Temperature Limits -4o to 131oF (-20o to 55oC)
Process Gas Up to 750oF (400oC), standard (higher available-contact
Alignment Verification Passive built-in through-the-lens system
Mounting Flanges 3 in. IPS, 150 lbs (56 kg) pipe flange
Ambient Light Immunity Solid-state electronic light modulation
Automatic
factory)
1-5
OPM 4000
Instruction Manual
IM-105-4000, Original Issue
August 2005
1-6
Instruction Manual
IM-105-4000, Original Issue
August 2005
Section 2 Installation
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . .page 2-2
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Mounting the Air Plenum and Weather Covers . . . . . . . . page 2-4
Before installing this equipment, read the “Safety instructions for the wiring and installation
of this apparatus” in Appendix A. Failure to follow safety instructions could result in serious
injury or death.
OPM 4000
Install all protective equipment covers and safety ground leads after installation. Failure to
install covers and ground leads could result in serious injury or death.
Before making any electrical connections, make sure the AC power supply is first switched
off. Failure to do so could cause personal injury or even death. Make sure that the voltage
and frequency of the AC supply match the designations on the analyzer component tags.
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OPM 4000
INSTALLATION
CONSIDERATIONS
Instruction Manual
IM-105-4000, Original Issue
August 2005
Choose an Installation
Site
Accessibility
Environment
The primary considerations for choosing a site for the OPM 4000 is
accessibility, ambient environmental conditions, and locating the unit to obtain
a representative sample of the process. The following general guidelines
should be considered.
Locate the instrument where it will provide safe access for periodic
maintenance and inspection. A platform or walkway is required for access to
the sensors and weather covers.
Locate the stack-mounted units in an area with ambient temperatures
between -4
temperature ranges.) Areas that are clean and dry are desirable. Avoid areas
with condensation.
Maintenance intervals are directly related to the installation environment.
Intervals can vary from 2 to 3 months in fairly clean environments, to twice a
month in dirty environments. Lens cleaning is a function of the ambient
conditions and cleanliness of the purge air.
Locate the instrument to avoid excessive vibration or shock.
Locate the control unit in an easily ac cessible area with temperatures
between 32
change controls, the unit should not be mounted higher than five feet from
floor level.
o
to +130oF (-20ο to 54oC). (Consult the factory for other
o
to 122oF (0o to 50oC). To permit the operator to read and/or
Stack Exit
MECHANICAL
INSTALLATION
Drawing Notes
Platforms
It is recommended to locate the transceiver at least two stack diameters from
the stack exit.
A review of the drawings and procedures provided will help to produce an
error free installation. However, there are important additional points that must
be observed. The beam of the instrument must be kept in a horizontal plane;
the transceiver cannot be rotated more than ±10
covers must be installed vertically level.
Installation and wiring diagrams are found at the end of this manual. Please
review all drawings prior to starting installation or wiring.
A platform or walkway must be available for access to the weather covers.
The optimum condition is to have the mounting flanges and weather covers
approximately 5 feet (1,5 m) above the floor. A minimum of 12 in. (305 mm)
from the bottom of the weather cover to the floor is required in order to
remove the air filters. Railings and other obstructions should allow the
weather cover to swing clear as shown in the installation drawings.
o
from vertical. The weather
2-2
Instruction Manual
IM-105-4000, Original Issue
August 2005
OPM 4000
Alignment of Stack
Flanges
Installation of Stack
Flanges
Stack flange alignment is described in Installation of Stack Flanges and is the
first step in successful installation. The final beam alignment adjustments are
described in the Beam Alignment Procedure.
For an opacity monitor, the customer is required to supply and install two 3 in.
IPS flanges at eye level directly across from each other. The flange faces,
mounted on pipe stubs, should be approximately 6 to 8 in. (152 to 203 mm)
from the stack or insulation. On completion of the installation, the flanges
must be aligned so that the total deviation of the light source flange relative to
a common centerline does not exceed ±1
not exceed ±3
Flanges should be mounted approximately 5 feet (1,5 m) up from the deck of
the platforms, roof or walk way.
At installations where conditions permit, this may be accomplished by using a
piece of 2-1/2 in. (63,5 mm) pipe suspended across the stack protruding far
enough to allow slipping the 3 in. flange pipe assemblies over each end and
welding in place as shown in Mounting: Under 6 ft (1,8 m) Diameter drawing
in Section 8.
Any deviation up to the previously specified limits can be adjusted during the
installation and alignment of the light source and retro reflector with the
system's alignment adjustments.
Where installations do not permit the use of the method mentioned above, the
following procedure will accomplish the same results. (See Mounting: Over 6
ft (1,8 m) Diameter drawing in Section 8). An alignment tool can be purchased
from the factory to ensure accurate alignment.
o
.
o
and the retro reflector flange does
Sample Area
Accurately locate one 3-1/2 in. (89 mm) diameter hole (large enough to
accept the 3 in. pipe) and the other hole approximately 1/2 in. (12,7 mm)
diameter, directly across from each other. Attach the alignment tool to the
flange/pipe assembly and insert the pipe into the 3-1/2 in. (89 mm) hole in the
stack wall. Align the assembly with the 1/2 in. (12,7 mm) diameter hole on the
opposite side by viewing through the alignment tool and weld the pipe in
place. Care must be exercised when welding to maintain alignment.
The 1/2 in. (12,7 mm) diameter hole should now be enlarged approximately
3-1/2 in. (89 mm) to accept the other flange/pipe assembly. Proceed in the
same manner, installing the assembly with the alignment tool attached, and
weld in place maintaining concentric alignment with the 3 in. pipe previously
installed on the opposite wall.
To achieve a representative sample, the accepted practice is to have the
measurement path of the instrument directly in the center of the stack. An
area should be chosen where the gases are not stratified in the stack or duct.
When installed near a bend, install the transceiver in the plane defined by the
bend. Avoid locations where large amounts of condensed water may be
present.
2-3
OPM 4000
MOUNTING THE AIR
PLENUM AND WEATHER
COVERS
Instruction Manual
IM-105-4000, Original Issue
August 2005
Control unit, Transceiver and Retro serial numbers must match.
After the installation site has been selected and the platform requirements
have been met, the mounting flanges should be installed and aligned as
described in Section 2, Installation of Stack Flanges. Flanges should be
installed with the mounting faces on the vertical plane.
1. Before installing the transceiver, retro reflector, or any type of weather
cover, remove the air plenum from both the transceiver and retro
reflector. Removal will make the installation easier with less chance of
damage while attaching the air plenums and optional weather covers
when provided.
Figure 2-1. Transceiver and
Retro Reflector Hinge Pins
Hinge Pin
2. If the transceiver and retro reflector have been shipped from the factory
with the air plenum attached, un-clip both hold down latches, swing
open and lift up and off the hinge pins (Figure 2-1). Place the
transceiver and retro in a safe place.
3. The air plenum is attached to the customer supplied 3 in. pipe flange by
four 2-1/2 in. (63,5 mm) long 5/8-11 bolts. Working from the 3 in. flange,
assemble the gasket then air plenum.
4. If you have weather covers remove the two weather cover hood hinge
pins located on the upper right and left hand corner of the hood. The air
plenum and weather cover are attached to the 3 in. pipe flange by four
2-1/2 in. (63,5 mm) long 5/8-11 bolts (Figure 2-2). Working from the 3 in.
flange, assemble the gasket, weather cover mounting plate, gasket, and
mating flange, and air plenum. Place the 5/8-11 bolt through the top hole
of the middle plate. Place a flat washer between the middle plate and
mating flange and pass the bolt through. Slip a split lock washer over
the bolt and secure with a nut. Repeat for the remaining three mounting
bolts.
5. Connect any wiring or air hoses.
2-4
Instruction Manual
IM-105-4000, Original Issue
August 2005
Figure 2-2. Air Plenum
OPM 4000
Transceiver and Retro
Reflector Assembly
Figure 2-3. Upper and Lower
Hinge Pins
3 in. 125# Flange
Air Plenum
Middle Plate
1. Attach the transceiver and retro reflector to the air plenum assembly by
placing them on the hinge pins (Figure 2-3).
Upper Hinge Pin
Lower Hinge Pin
2. Close transceiver and retro and secure in place with the two hold down
latches.
3. The air-purge blowers should be powered up at this time to prevent
stack particulate from accumulating in the nipple and air-purge housing.
If installed location has a positive pressure the air-purge system must be used continuously
during installation to prevent process gases from contaminating optical surfaces or over
heating instrument electronics. If the system is shut off for more than momentary
interruptions, the instrument may be damaged. Failure to provide contin uous air-purge ma y
void the warranty.
All wiring from the control unit to the transceiver should be completed at this
time.
2-5
OPM 4000
Instruction Manual
IM-105-4000, Original Issue
August 2005
BEAM ALIGNMENT
PROCEDURE
Figure 2-4. Service Module
Switch Location
NOTE
Alignment can not be done unless the power is applied to the stack mounted
service module. The control unit does not have to be connected or powered.
For alignment accuracy, the stack should be at normal temperature.
NOTE
Alignment should be completed before instrument calibration. For alignment
accuracy, the stack should be at normal temperature.
Maintenance module switches (Figure 2-4) should be in the normal type
operating positions.
2-6
• Zero/Operate - Operate
• Span/Operate - Operate
• Normal/Test - Normal
2
• Opacity/T
1. If not already on, turn on the power to all air purge systems and service
module.
2. Align the reflector mating flange so it is level and parallel to the 3 in. 150
lb mounting flange. Use the 3 adjusting bolts on the air purge plenum
flange until this is accomplished. The adjusting bolts have nylon locking
inserts to prevent loosening by vibration.
- Opacity
Instruction Manual
IM-105-4000, Original Issue
August 2005
Figure 2-5. Alignment of the
Transceiver.
OPM 4000
3. Move to the transceiver, and determine monitor alignment by looking
through the viewing port located on the rear of the transceiver and
observing whether the beam image is in the center of the cross hair
(bulls-eye) an shown in Figure 2-5.
Adjusting Bolts
2-7
OPM 4000
Instruction Manual
IM-105-4000, Original Issue
August 2005
Air Flow Switch
Control Unit
Figure 2-6. Control Unit
If you have an airflow alarm when the system is powered, check the airflow
switch. With the blower running and the so urce under normal conditions,
disconnect the leads of the switch and place an ohmmeter across them. The
switch should be closed, less than 2 ohms, if flow is enough to over-come
stack pressure and blower inlet is clear. Cover the air cleaner inlet and verify
the switch opens. Replace the leads when the test is complete.
Mount the control unit (Figure 2-6) at eye level for best viewing of the display.
Cut out for panel mounting is shown in the drawing section. Insert the control
unit through the cut-out hole. Insert the panel mounting hardware in the slots
provided in the top and bottom of the control unit from the rear. Tighten the
screws until the control unit is securely held in place.
Wire the control unit per drawing section and energized power.
2-8
Instruction Manual
IM-105-4000, Original Issue
August 2005
Section 3 Startup and Calibration
Before Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-1
Stack Exit Correlation Computation . . . . . . . . . . . . . . . . . page 3-2
Startup Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-2
Verifying Instrumen t Operation and Configuration . . . . .page 3-2
Edit Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 3-2
Factory OPLR Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Quick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3-3
Zero/Span Calibration Check . . . . . . . . . . . . . . . . . . . . . . . page 3-4
OPM 4000
BEFORE STARTUP
You must complete the following before startup is attempted.
1. Measure and record flange-to-flange distance to verify it is the same as
the final check out sheet.
2. If you are using a recorder, DAS, etc., DO NOT CONNECT THEM
NOW. Outputs and inputs from other sources should be left off until
system has been completely checked according to the following
instructions. After system operation has been verified, connect and test
external connections.
3. Read the instructions first to familiarize yourself with the instrument
before attempting startup.
4. The air purge and weather cover system, transceiver, retro reflector,
and service module must be installed and power applied.
5. Control unit must be installed and wired to the service module and
customers equipment as applicable.
6. All wiring and mechanical installations must be complete per drawings
provided in this manual. All wiring must be checked and power applied
to both the control unit and the stack maintenance module.
7. Beam alignment procedure has been completed.
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