Manual: OPM 2001 Transmissometer Opacity / Dust Density Transmitter-Orig. Issue | Rosemount
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Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
Transmissometer Opacity/Dust
Density Transmitter
http://www.processanalytic.com
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 to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and integrated 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 prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Rosemount Analytical repre-
sentative for clarification.
• Follow all warnings, cautions, and instructions marked on and supplied with the product.
• Inform and educate your personnel in the proper installation, operation, and mainte-
nance of the product.
• Install your equipment as specified in the Installation Instructions of the appropriate In-
struction 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 to install, 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.
The information contained in this document is subject to change without notice.
Emerson Process Management
Rosemount Analytical Inc.
Process Analytic Division
1201 N. Main St.
Orrville, OH 44667-0901
T (330) 682-9010
F (330) 684-4434
e-mail: gas.csc@EmersonProcess.com
http://www.processanalytic.com
Model OPM 2001
PREFACE........................................................................................................................ P-1
Definitions ........................................................................................................................P-1
Safety Instructions .......................................................................................................... P-2
Glossary of Terms ......................................................................................................... P-3
1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1
1-1 Component Checklist of Typical System (Package Contents) .................................. 1-1
1-2 System Overview............................................................................................................ 1-1
1-3 Method of Measurement................................................................................................ 1-6
1-4 Specifications................................................................................................................... 1-7
1-5 System Startup Procedure ............................................................................................ 1-9
2-0 INSTALLATION .............................................................................................................. 2-1
2-1 General ............................................................................................................................ 2-1
2-2 Choosing a Location ...................................................................................................... 2-1
2-3 Calibration........................................................................................................................ 2-2
2-4 Mounting Flanges to Stack ........................................................................................... 2-2
2-5 Lifting and Handling .......................................................................................................2-3
2-6 Mounting Instructions ..................................................................................................... 2-4
2-7 Monitoring Opacity in High Temperature Applications ............................................... 2-7
2-8 Monitoring Opacity at Low Ambient Temperatures ................................................... 2-9
2-9 System Wiring Installation ............................................................................................. 2-9
Instruction Manual
IB-106-2001 Original Issue
July 2001
TABLE OF CONTENTS
3-0 OPERATION ...................................................................................................................3-1
3-1 Overview.......................................................................................................................... 3-1
3-2 HART Communicator Signal Line Connections .......................................................... 3-1
3-3 Offline and Online Operations ...................................................................................... 3-4
3-4 HART Operator Interface Description ......................................................................... 3-4
3-5 Using the HART Interface............................................................................................. 3-6
3-6 PROCESS VARIABLES Menu ...................................................................................... 3-7
3-7 DIAG/SERVICE Menu .................................................................................................. 3-10
3-8 BASIC SETUP Menu ................................................................................................... 3-19
3-9 DETAILED SETUP Menu .............................................................................................. 3-22
3-10 REVIEW Menu.............................................................................................................. 3-29
3-11 HART Communicator Menu Tree for OPM 2001 ................................................... 3-29
4-0 ALIGNMENT ...................................................................................................................4-1
4-1 Optical Alignment ...........................................................................................................4-1
4-2 Objective Lens Adjustment............................................................................................ 4-4
5-0 TRANSCEIVER AND RETROREFLECTOR MODULES ............................................ 5-1
5-1 Transceiver Module ........................................................................................................ 5-1
5-2 Retroreflector Module ..................................................................................................... 5-8
5-3 Purge Air Failure Flow Switch ..................................................................................... 5-9
5-4 Air Lens Assembly....................................................................................................... 5-10
Rosemount Analytical Inc. A Division of Emerson Process Management i
Instruction Manual
IB-106-2001 Original Issue
July 2001
6-0 INTELLIGENT ELECTRONICS ..................................................................................... 6-1
6-1 General ............................................................................................................................ 6-1
6-2 Intelligent Electronics (General Purpose) ..................................................................... 6-1
6-3 Type 4x Intelligent Electronics (Option)...................................................................... 6-5
7-0 MAINTENANCE AND SERVICE .................................................................................. 7-1
7-1 General ............................................................................................................................ 7-1
7-2 Preventative Maintenance .............................................................................................. 7-1
7-3 Repair .............................................................................................................................. 7-3
7-4 Zero Jig........................................................................................................................... 7-9
7-5 Fuse Replacement ....................................................................................................... 7-10
8-0 TROUBLESHOOTING .................................................................................................... 8-1
8-1 General ............................................................................................................................ 8-1
8-2 System Mode Indicators ................................................................................................ 8-1
8-3 Diagnostics ...................................................................................................................... 8-1
8-4 Test Procedures .............................................................................................................8-6
9-0 RETURN OF MATERIAL .............................................................................................. 9-1
Model OPM 2001
10-0 REPLACEMENT PARTS ............................................................................................. 10-1
11-0 APPENDICES ............................................................................................................... 11-1
Appendix A ................................................................................................................... 11-1
Appendix B ................................................................................................................. 11-11
Appendix C ................................................................................................................. 11-13
12-0 INDEX............................................................................................................................ 12-1
13-0 DRAWINGS AND SCHEMATICS............................................................................... 13-1
ii Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Figure 1-1. Standard Model OPM 2001 Transmissometer
Opacity/Dust Density Transmitter .......................................................................... 1-2
Figure 1-2. Component Relationships...................................................................................... 1-3
Figure 1-3. Calibration Dimensions .......................................................................................... 1-4
Figure 1-4. Relationship of Opacity, Transmittance, and Optical Density................................ 1-4
Figure 1-5. Example Relationship of Extinction and Dust Concentration ................................ 1-5
Figure 2-1. Transmitter Location Considerations ..................................................................... 2-1
Figure 2-2. Transmitter Location .............................................................................................. 2-2
Figure 2-3. Stack Flange Installation........................................................................................ 2-3
Figure 2-4. Lifting and Handling ...............................................................................................2-4
Figure 2-5. Stack Installation Dimensions ................................................................................ 2-5
Figure 2-6. Intelligent Electronics Mounting Dimensions ......................................................... 2-6
Figure 2-7. Insulation and Cooling Fin Installation................................................................... 2-8
Figure 2-8. Optional Purge Air Heater.................................................................................... 2-10
Figure 2-9. Customer Connections for OPM 2001
with General Purpose Intelligent Electronics (Sheet 1 of 2) ................................ 2-12
Figure 2-9. Customer Connections for OPM 2001
with General Purpose Intelligent Electronics (Sheet 2 of 2) ................................ 2-13
Figure 2-10. Customer Connections for OPM 2001
with Optional Type 4X Intelligent Electronics (Sheet 1 of 2) ............................... 2-14
Figure 2-10. Customer Connections for OPM 2001
with Optional Type 4X Intelligent Electronics (Sheet 2 of 2) ............................... 2-15
Figure 2-11. General Purpose Intelligent Electronics Relay
and Analog Output Connections.......................................................................... 2-16
Figure 3-1. HART Terminal Connections ................................................................................. 3-2
Figure 3-2. Signal Line Connections, ≥250 Ohms Lead Resistance ....................................... 3-3
Figure 3-3. Signal Line Connections, <250 Ohms Lead Resistance ....................................... 3-4
Figure 3-4. HART Communicator Operator Interface .............................................................. 3-4
Figure 3-5. On-line Menu ......................................................................................................... 3-6
Figure 3-6. LCW Locations....................................................................................................... 3-8
Figure 3-7. Zero Jig and EPA Filter Placement...................................................................... 3-16
Figure 3-8. lx and lt Stack Dimensions................................................................................... 3-21
Figure 3-9. Sectored LCW2 ................................................................................................... 3-23
Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 1 of 3) ............................................ 3-30
Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 2 of 3) ............................................ 3-31
Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 3 of 3) ............................................ 3-32
Figure 4-1. Optical Alignment................................................................................................... 4-2
Figure 4-2. View of Crosshairs and Tolerance Areas in Optical Alignment Sight.................... 4-3
Figure 4-3. Objective Lens Adjustment .................................................................................... 4-5
Figure 5-1. Transceiver Module - Exploded View .................................................................... 5-0
Figure 5-2. Transceiver Optical Assembly - Exploded View .................................................... 5-2
Figure 5-3. Stack Light Path..................................................................................................... 5-3
Figure 5-4. Ambient Light Path.................................................................................................5-4
Figure 5-5. Dark Mode ............................................................................................................. 5-4
Figure 5-6. Lamp Light Path..................................................................................................... 5-5
Figure 5-7. Zero Jig Mounting Location ................................................................................... 5-5
Figure 5-8. Effective Spectral Response Curve ....................................................................... 5-6
Figure 5-9. Optical Mounting Channel (with Boards) .............................................................. 5-6
Figure 5-10. Detector Circuit ...................................................................................................... 5-7
Figure 5-11. Stack LON Board ...................................................................................................5-7
Instruction Manual
IB-106-2001 Original Issue
July 2001
LIST OF ILLUSTRATIONS
Rosemount Analytical Inc. A Division of Emerson Process Management iii
Instruction Manual
IB-106-2001 Original Issue
July 2001
Figure 5-12. Retroreflector and Air Lens Assembly ................................................................... 5-8
Figure 5-13. Air Lens Assembly and Purge Air Failure Flow Switch.......................................... 5-9
Figure 5-14. Air Lens Assembly - Exploded View .................................................................... 5-10
Figure 6-1. General Purpose Intelligent Electronics - Exploded View ..................................... 6-1
Figure 6-2. IG-1 Software Board .............................................................................................. 6-2
Figure 6-3. HART Daughter Board........................................................................................... 6-3
Figure 6-4. HART Daughter Board Relay Contact Configurations........................................... 6-5
Figure 6-5. Type 4X Intelligent Electronics - Exploded View ................................................... 6-6
Figure 6-6. Termination Board ................................................................................................. 6-7
Figure 6-7. Power Supply......................................................................................................... 6-7
Figure 7-1. External Filters - Exploded View ............................................................................ 7-2
Figure 7-2. Internal Filter - Exploded View............................................................................... 7-3
Figure 7-3. Lamp Replacement................................................................................................ 7-4
Figure 7-4. Detector/Amplifier Board........................................................................................ 7-5
Figure 7-5. Beam Splitter Adjustment and LCW Replacement................................................ 7-6
Figure 7-6. V
Figure 7-7. Zero Jig Adjustment and Locking Screws ............................................................ 7-9
Figure 8-1. PS1 and PS2 Test Points ...................................................................................... 8-6
LAMP
Model OPM 2001
Adjustment ................................................................................................... 7-7
LIST OF TABLES
Table 3-1. Function Keys ........................................................................................................ 3-5
Table 3-2. Action Keys............................................................................................................ 3-6
Table 3-3. System Status Modes............................................................................................ 3-7
Table 3-4. FLD DEVICE VOLTS Submenu ............................................................................ 3-8
Table 3-5. LCW States ............................................................................................................ 3-8
Table 3-6. OUTPUT VARIABLES Submenu........................................................................... 3-9
Table 3-7. REF. VOLTAGES Submenu................................................................................ 3-13
Table 3-8. FLTR CHK Submenu........................................................................................... 3-15
Table 3-9. SETUP CLOCK Submenu ................................................................................... 3-19
Table 3-10. PV, SV, and TV RANGE VALUES Submenu ...................................................... 3-20
Table 3-11. DEVICE INFO Submenu. .................................................................................... 3-21
Table 3-12. RELAY CONFIG Submenu.................................................................................. 3-22
Table 3-13. ZERO/SPAN CHECK Submenu .......................................................................... 3-24
Table 3-14. LCW Sector Status .............................................................................................. 3-25
Table 3-15. AVERAGES Submenu......................................................................................... 3-26
Table 3-16. ALARMS Submenu.............................................................................................. 3-27
Table 3-17. DUST SETUP Submenu...................................................................................... 3-28
Table 3-18. REVIEW Menu..................................................................................................... 3-29
Table 8-1. Diagnostic Indicators ............................................................................................. 8-2
Table 8-2. Troubleshooting Chart ........................................................................................... 8-3
Table 10-1. Replacement Parts for General Purpose Intelligent Electronics ......................... 10-4
Table 10-2. Replacement Parts for Type 4X Intelligent Electronics ....................................... 10-4
Table 10-3. Replacement Parts for Transceiver and Retroreflector Modules ........................ 10-4
Table 10-4. Replacement Parts for Transceiver Module ........................................................ 10-5
Table 10-5. Replacement Parts for Retroreflector Module ..................................................... 10-5
Table 10-6. Replacement Parts Kit ......................................................................................... 10-6
Table 10-7. Certified Neutral Density Filters ........................................................................... 10-6
iv Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
The purpose of this manual is to provide information concerning the components, functions, installation and maintenance of the Model OPM 2001 Transmissometer Opacity/Dust
Density Transmitter.
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.
Instruction Manual
IB-106-2001 Original Issue
July 2001
PREFACE
DEFINITIONS
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 essential operating procedure,
condition, or statement.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETIN
NOTE TO USERS
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
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.
Rosemount Analytical Inc. A Division of Emerson Process Management P-1
Instruction Manual
IB-106-2001 Original Issue
July 2001
FOR THE WIRING AND INSTALLATION
The following safety instructions apply specifically to all EU member states. They should
be strictly adhered to in order to assure compliance with the Low Voltage Directive. NonEU states should also comply with the following unless superseded by local or National
Standards.
1. Adequate earth connections should be made to all earthing points, internal and external,
where provided.
2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.
The integrity of all earth terminals must be maintained at all times.
3. Mains supply cords should comply with the requirements of IEC227 or IEC245.
Model OPM 2001
IMPORTANT
SAFETY INSTRUCTIONS
OF THIS APPARATUS
4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.
5. All cable glands used should be of such internal dimensions as to provide adequate cable
anchorage.
6. To ensure safe operation of this equipment, connection to the mains supply should only be
made through a circuit breaker which will disconnect all circuits carrying conductors during a
fault situation. The circuit breaker may also include a mechanically operated isolating switch.
If not, then another means of disconnecting the equipment from the supply must be provided
and clearly marked as such. Circuit breakers or switches must comply with a recognized
standard such as IEC947. All wiring must conform with any local standards.
7. Where equipment or covers are marked with the symbol to the right, hazardous voltages are likely to be present beneath. These covers should only be
removed when power is removed from the equipment — and then only by
trained service personnel.
8. Where equipment or covers are marked with the symbol to the right, there is a
danger from hot surfaces beneath. These covers should only be removed by
trained service personnel when power is removed from the equipment. Certain surfaces may remain hot to the touch.
9. Where equipment or covers are marked with the symbol to the right, refer to
the Operator Manual for instructions.
10. All graphical symbols used in this product are from one or more of the following standards: EN61010-1, IEC417, and ISO3864.
P-2 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Air Window
A device that blows purge air out of the transceiver and retroreflector module into the stack, preventing the stack gasses from entering the modules. This maintains a clean space between the
module optics and flue gasses, preventing particulate buildup on the optics. The air window contains a manually sliding seal that is used to isolate the module from the stack when purge air
must be turned off. The air window also contains a ball joint used to align the optics.
Corner Cube
A device used by the OPM 2001 as a retroreflector. Corner cubes come in different sizes based
on the path length between the transceiver and retroreflector modules.
EPA
Environmental Protection Agency.
Extinction
See optical density.
FSK (Frequency Shift Keying)
The sumperimposing of a high frequency digital communication signal on an electrical signal. The
HART communication protocol uses FSK to communicate between the hand held unit and the
intelligent electronics over the 4-20 mA analog output line. The HART signal does not affect the
4-20 mA analog output, since no energy is added to or removed from the loop.
Instruction Manual
IB-106-2001 Original Issue
July 2001
GLOSSARY OF TERMS
HART Communicator
A hand-held communications and interface device that can communicate with HART compatible
instrumentation. The HART communicator can be used to view data and configure and calibrate
the OPM 2001. The HART communicator uses the frequency shift keying technique to communicate to other HART compatible device over the 4-20 mA analog output line.
In Situ
The measuring of the parameters of a process without extracting the sample from the process
stream.
LCW (Liquid Crystal Window)
A solid state device that changes from translucent, scattering and diffusing light, to transparent
when an electrical signal is applied. This allows the OPM 2001 to control the path of light through
the transceiver module with no moving parts.
lf
The flange to flange distance between the transceiver and retroreflector modules when installed
on the stack.
lt
The inside stack diameter at the transmitter location.
lx
The inside stack diameter at the stack exit.
Rosemount Analytical Inc. A Division of Emerson Process Management P-3
Instruction Manual
IB-106-2001 Original Issue
July 2001
lx/lt
The ratio between the inside diameter of the stack at the stack exit and at the transmitter location.
This value is used to correct the transmitter reading to calculate stack exit opacity.
Neutral Density Filter
An optical filter used to reduce the intensity of light without changing its color.
Opacity
The amount of light being scattered or absorbed by particles in the path of a beam of light.
Optical Density (OD)
The degree of translucence of an optical medium. Optical density is expressed as:
OD = -log(transmittance/100). An optical density of 1 is equivalent to a 10% transmittance, or an
opacity of 90%. Also called Extinction.
Photopic Region
That region of the light spectrum visible to the human eye.
Purge Air
Filtered air provided by the purge air blowers. Purge air is used by the air windows to prevent the
build-up of particulate on the module optics.
Model OPM 2001
Retroreflector
A device that reflects light in such a way that its angle is parallel to the incoming, or incident, rays.
The OPM 2001 uses a corner cube in the retroreflector module to reflect the light beam from the
transceiver module back to the transceiver module.
Ringelmann Scale
A scale ranging from 0 to 5 used by observers to rate the opacity of stack emissions. Each number on the scale equals approximately 20% opacity, i.e. a Ringelmann number of 2 equals 40%
opacity. The Ringelmann scale is very subjective, as it can be influenced by sky haze, the position of the sun, or interpretation of the observer.
Transmissometer
An instrument that uses opacity to measure the particulate level of stack emissions. Sometimes
referred to as a dust density transmitter.
Transmittance
The complimentary function of opacity. Percent opacity plus Percent transmittance always equals
100%.
Zero Jig
A device used to provide a zero opacity reference for the OPM 2001 without the need to remove
the transceiver module from the stack. Also holds neutral density filters for performing span
checks.
P-4 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
DESCRIPTION AND SPECIFICATIONS
Instruction Manual
IB-106-2001 Original Issue
July 2001
SECTION 1
1-1 COMPONENT CHECKLIST OF TYPICAL
SYSTEM (PACKAGE CONTENTS)
A typical Rosemount Model OPM 2001 Transmissometer Opacity/Dust Density Transmitter
should contain the items shown in Figure 1-1.
1-2 SYSTEM OVERVIEW
a. Scope
This instruction bulletin is designed to supply details needed to install, operate, and
maintain an OPM 2001.
b. Reason for Measuring Opacity
Opacity refers to the amount of light being
scattered or absorbed by particles in the
light beam path. An opacity or dust density
transmitter (also called a transmissometer)
measures the particulate level of stack
emissions. One of the most common reasons for measuring opacity is to comply with
Environmental Protection Agency (EPA) or
other national requirements. Federal regulations for new emission sources and many
state regulations for both new and existing
sources specify maximum limits for stack
emission opacity.
transmitter gives accurate, immediateresponse data, corrective actions can be
taken as soon as problems occur. This data
serves not only the compliance requirement
of pollution regulation standards but also as
a means to achieve improved efficiency and
operating profit.
Originally, a trained smoke reader determined the particulate level of stack emissions solely by observation. The opacity of
the plume was judged in reference to a
standard Ringelmann scale of 0 to 5. These
determinations tended to be influenced by
several sources of error such as sky haze,
sun position, and the subjective determination of the observer. These sources of error,
especially at lower opacity levels, can produce highly variable readings even when
performed by a trained observer.
c. System Description
The OPM 2001 is an in situ optical transmitter that uses a visible light beam in the
photopic region (peak and mean responses
in the 500 to 600 nm range) to measure
opacity in stack emissions. The OPM 2001
contains no moving parts except for blower
motors, which eliminates sources of wear
and possible failure.
A transmissometer can be used in a variety
of applications. Those applications include
monitoring the efficiency of emission control
systems, detecting broken bags in baghouses, and determining the time rapping
cycles for electrostatic precipitators. Another
application is to gauge the effectiveness of
injecting flue gas conditioning agents used
to improve electrostatic precipitator performance.
Opacity data can also serve as a rough indicator of combustion efficiency. Extreme
changes in opacity may indicate inefficient
combustion or boiler problems. Because the
Rosemount Analytical Inc. A Division of Emerson Process Management 1-1
Federal regulations and many state and local laws use visual observation as a reference. Thus, for a true correlation, it is
important that transmissometers use the
same spectral response range as the human eye. This portion of the spectrum is
called the photopic response range. Since
visual readings are taken at the stack exit,
the OPM 2001 compensates for the difference between stack diameter at the exit and
stack diameter at the installation site.
The OPM 2001 consists of a transmitter/
receiver (transceiver) module, a retroreflector module, and intelligent electronics.
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
2
HART
MAN4275A00
October1994
Communicator
o
FISHER-ROSEMOUNT
14
1
15
English
TM
3
4
13
12
5
9
11
1. Transceiver Module
2. Retroreflector Module
3. General Purpose Intelligent Electronics
4. Type 4X Intelligent Electronics (optional)
5. Optical Alignment Sight (optional)
6. 6 in. Optical Extension (optional)
7. LON Communication Test Cable
8. Power Supply (optional)
Figure 1-1. Standard Model OPM 2001 Transmissometer
Opacity/Dust Density Transmitter
10
6
8
7
35560026
9. 751 Field Signal Indicator (optional)
10. Communication Cable (optional)
11. Purge Air Failure Flow Switch Cable (optional)
12. HART Communications Package (optional)
13. Instruction Bulletin
14. Power Test Cable
15. Zero Jig (optional)
1-2 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
July 2001
The transceiver and retroreflector modules are mounted directly opposite of
each other on the stack (Figure 1-2). The
transceiver projects a controlled beam of
light across the stack. The corner cube
bounces the light back along a parallel
path to the transceiver. Particles in the
gas stream cause a certain amount of the
light to be scattered and absorbed. This
amount varies depending on the particulate content of the gas stream and the
particle type and size.
The light then strikes a detector, which converts the light into a voltage that can be
TRANSCEIVER
MODULE
LAMP
OBJECTIVE
LENS
processed. The detector signal is amplified
by an independently powered detector/
amplifier board. The amplified signal is then
digitized and transmitted to the intelligent
electronics. The intelligent electronics calculates opacity, sends commands to the
transceiver, and provides an operator interface via HART communications.
Because the beam passes through the
stack twice (once in each direction), the resulting value is a double-pass transmittance
measurement. By passing through the
smoke twice, sensitivity to low opacity levels
is increased.
WINDOW
RETROREFLECTOR
STACK
EXHAUST
CORNER
CUBE
BEAM
SPLITTER
NOTES: BLOWER MOTORS ARE NOT SHOWN.
COMMUNICATIONS CABLE MAY BE UP TO 1 MILE LONG.
DETECTOR
Figure 1-2. Component Relationships
WINDOW
ACCESS
PLATE
COMMUNICATIONS
CABLE TO AND
FROM TRANSCEIVER
INTELLIGENT
ELECTRONICS
HART
COMMUNICATOR
35560016
Rosemount Analytical Inc. A Division of Emerson Process Management 1-3
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
The measurement value is compared to a
reference value previously determined with
no smoke in the light path. The resulting ratio is the transmittance value for the measurement path. This ratio can then be
converted to units of optical density, stack
exit opacity, and dust concentration.
The reference value depends on the lf dimension shown in Figure 1-3. Also illustrated are dimensions lx and lt, which are
necessary for OPM 2001 calibration and
setup. These dimensions are defined as
follows:
lx = inside stack diameter at stack exit.
lt = inside stack diameter at the trans-
mitter location.
lf = flange to flange distance between
the transceiver and retroreflector
unit. It is also the distance that must
be used to calibrate the unit offline.
The LX/LT parameter is entered in the
BASIC SETUP submenu of the HART
Communicator. See paragraph 3-8c for
more information.
smoke opacity is sometimes referred to in
Ringelmann numbers. By definition, Ringelmann No. 1 is equivalent to 20% opacity with
the opacity increasing 20% for each subsequent number. This scale is based on a
single-pass value as would be read by a human observer.
The relationship between opacity, transmittance, and optical density (or extinction) is
shown graphically in Figure 1-4 and in the
table in Appendix A. One hundred percent
transmittance is equivalent to 0% opacity or
zero optical density. Opacity and optical
density are logarithmically related in such a
way that zero optical density equals zero
opacity; an optical density of one is equal to
90% opacity; an optical density of two is
equal to 99% opacity, etc.
Opacity is a complementary function of
transmittance. It is a measurement of the
amount of light that is blocked or absorbed
by the flue gases. The measurement of
Figure 1-3. Calibration Dimensions
Figure 1-4. Relationship of Opacity,
Transmittance, and Optical Density
1-4 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
July 2001
The OPM 2001 automatically compensates
for the effects of ambient light, zero drift,
and component aging with every measurement cycle. Four separate voltages produced in each measurement cycle are
compared against two sets of reference
voltages taken either off stack or in a clear
stack. The first set is taken in 0% opacity
conditions, and the second set is taken in
simulated 100% opacity conditions. The resulting reference zero and span voltages
produce a reference point by which the
transmitter judges current operation.
d. System Considerations
All procedures in this manual must be performed carefully in order to gain the maximum benefit from the OPM 2001. Proper
maintenance is important for maintaining
signal accuracy and will greatly increase instrument life.
e. Dust Concentration Measurements
The OPM 2001 uses an optical technique to
measure opacity and extinction. Equating
this to a dust concentration measurement
requires additional iso-kinetic sampling in
order to calibrate the unit. Iso-kinetic sampling involves taking a series of actual dust
concentration measurements in the flue and
comparing these with the extinction reading
from the OPM 2001. From this comparison,
a graph can be plotted (Figure 1-5) that
shows the relationship between extinction
and dust measurement exclusive to that
particular application. This method takes
into account the variation in dust sizes and
densities in different applications. The procedure is described in the following
standards:
concentration and mass flow rate of
particulate matter in gas-carrying ducts
- manual gravimetric method.
2. ISO/DIS 10155 Stationary Source
Emissions. Automated monitoring of
mass concentration of particles - performance characteristics, test methods,
and specifications.
1. ISO 9096 Stationary Source Emissions. Determination of mass
Rosemount Analytical Inc. A Division of Emerson Process Management 1-5
Figure 1-5. Example Relationship of Extinction
and Dust Concentration
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
1-3 METHOD OF MEASUREMENT
The following sequence of steps determines the
relationship of dust concentration to extinction
readings:
a. After the OPM 2001 has been installed and
is functioning properly, a series of gravimetric measurements are taken using a
standard method as outlined in ISO 9096.
As each measurement is taken, the
equivalent extinction reading on the OPM
2001 is recorded.
b. The recorded data is plotted and presented
in accordance with methods outlined in ISO
10155 or a relevant local standard. This information is used to calculate the “extinction
coefficient” that determines the relationship
between extinction and dust concentration
measurement.
c. A typical graph and dust concentration cal-
culation (Figure 1-5) shows a linear
relationship between extinction and dust
concentration. The calibration curve can be
linearized and represented by the following
equation:
DC = kE + c
Where:
DC = dust concentration
k = slope of dust concentration by ex-
tinction (determined from stack dust
sampling test data)
c = y intercept of dust concentration
(determined from stack dust sampling test data)
E = Extinction (measured variable by
OPM 2001)
The values for k and c are then entered in
the DUST SETUP submenu of the HART
Communicator to calculate the dust con-
centration (DC) from the extinction value.
Refer to paragraph 3-9e for more
information.
1-6 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
1-4 SPECIFICATIONS
Electrical:
Input Voltage Requirements ......................... 100/115/220/240 VAC, 50/60 Hz
Power Requirements..................................... 400 watts to transceiver, including 300 watt heater.
Wiring ............................................................ Two twisted pair (Belden 8162, 8163, or equivalent);
Electrical Classification ................................. Category II
Environmental:
Ambient Operating Temperature .................. -40° to 130°F (-40° to 55°C)
Flue Gas Temperature .................................. Maximum 1000°F (538°C); Minimum 220°F (104°C);
Flue Gas Pressure ........................................ Maximum 10 in. (254 mm) WC with supplied blowers
Pathlength ..................................................... User-definable from 3 to 26 ft (0.9 to 7.9 m)
Physical:
Optical System .............................................. Double-pass multiple lens optical system with solid
Light Source .................................................. Gas-filled incandescent bulb
System Shipping Weight ............................... 356 lbs (161.5 kg)
Instruction Manual
IB-106-2001 Original Issue
July 2001
The blowers are separately powered and rated at
1/2 HP @ 60 Hz or 1/3 HP @ 50 Hz (5.6 A @ 115
VAC or 3.1 A @ 240 VAC, 50 Hz).
maximum 5000 ft (1524 m) of cable between transceiver and intelligent electronics.
Non-condensing.
state electronic light modulation; utilizes liquid crystal
windows.
Transceiver and Retroreflector:
Enclosure Type ............................................. Weather housings are moisture-proof. The trans-
ceiver assembly is designed for Type 4X
environments.
Dimensions ................................................... Height: 28.77 in. (731 mm)
Width: 12.5 in. (318 mm)
Depth: 33.94 in. (862 mm)
Weight ........................................................... Transceiver: 80 lbs (36.3 kg)
Retroreflector: 40 lbs (18.1 kg)
Optical Alignment Sight ................................. Visual alignment sighting indicator utilizing cross-
hairs.
Air Lens Assembly:
Mounting........................................................ Flange mounted to enclosure mounting plate
Dimensions ................................................... Diameter: 11 in. (280 mm)
Length: 6 in. (150 mm)
Weight: 18 lbs (8 kg)
Blower Motor ................................................. Maximum volume 40.0 cfm @ 10 in. H
Weight ........................................................... 29 lbs (13 kg)
Intelligent Electronics:
Enclosure Type ............................................. General Purpose
Optional Type 4X
Ambient Operating Temperature .................. 40° to 120°F (4° to 50°C)
-40° to 120°F (-40° to 50°C) for optional Type 4X
intelligent electronics with heater and thermostat
Dimensions ................................................... Height: 2.72 in. (69.1 mm)
Width: 7.00 in. (177.8 mm)
Depth: 5.13 in. (130.3 mm)
O
2
Rosemount Analytical Inc. A Division of Emerson Process Management 1-7
Instruction Manual
IB-106-2001 Original Issue
July 2001
Weight ........................................................... 10 lbs (4.54 kg)
Voltage .......................................................... 24 ±1 VDC
Power ............................................................ 25 watts (Optional heater in Type 4X intelligent
electronics adds 300 watts.)
Contact Rating .............................................. 30 VDC, 2 A; 110 VDC, 0.3 A; 125 VAC, 0.5 A
Operational:
The OPM 2001 meets EPA design and performance requirements as specified in 40 CFR, Part 60, Appendix B, Performance Specification 1. The OPM 2001 also meets the performance audit requirements of EPA
Method 203.
Output Ranges .............................................. Continuously adjustable (field adjustable)
Accuracy........................................................ ±1% opacity (accuracy of ±1% opacity in normal op-
erating areas, up to 70% opacity reading. Above
70% opacity reading, accuracy of ±2% opacity ab-
solute).
Resolution ..................................................... <0.1% opacity
Response Time ............................................. <10 seconds
Calibration Error ............................................ <2% opacity
Zero Drift ....................................................... <2% opacity in 3 months
Calibration Drift ............................................. <2% opacity in 3 months
Spectral Response ........................................ 400 to 700 nm (less than 10% outside of this re-
gion); 500 to 600 nm peak and mean spectral
response.
Angle of View ................................................ <2 degrees
Angle of Projection ........................................ <2 degrees
Zero Check.................................................... Automatic verification
Span Check................................................... Automatic verification
Calibration Filter Access ............................... Provided for EPA verification
Measurement Units ....................................... Opacity, transmittance, optical density, extinction,
and dust concentration.
Signal Averaging ........................................... 13 selectable averages: 0.25, 1, 2, 3, 4, 5, 6, 10, 12,
15, 20, 30, and 60 minutes.
Automatic Lamp Compensation .................... Included
Automatic Calibration Verification ................. User-selectable, 1 to 1440 minutes
Digital Input ................................................... Contact input for remote initiation of zero/span check
Analog Outputs ............................................. Three linear isolated outputs 4-20 mA; 900 ohms
maximum (user-definable).
Contact Outputs ............................................ Six SPST relays, including two selectable alarms
Digital Communications Link......................... Communications link between transceiver and intel-
ligent electronics processor, 78 k baud.
Selectable Parameters.................................. Measurement units
Signal averaging
Optical Path Length Ratio (OPLR)
Analog output signal selection
Alarm settings
Manual calibration
Computer-assisted EPA filter chec
Certification ................................................... Supplied with Manufacturers EPA
Certificate of Compliance (option)
Vibration/Expansion Cross Hair Criteria ....... Within circle of 2% opacity
Vibration Frequency...................................... <60 cps
Vibration Frequency Magnitude .................... <0.0025 in. at 60 Hz
Model OPM 2001
1-8 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
July 2001
1-5 SYSTEM STARTUP PROCEDURE
Use the following steps to start the OPM 2001.
If the opacity transmitter is installed to meet the
requirements of EPA regulation 40 CFR, Part
60, Appendix B, Specification 1, follow this procedure prior to installing the opacity transmitter
on the stack (see 40 CFR, Part 60, Appendix B,
Specification 1, Section 7, PERFORMANCE
SPECIFICATION VERIFICATION PROCEDURE). It is also recommended that certain
parts of these startup procedures be repeated
once the unit is mounted on the stack or duct.
a. Turn on power to the transceiver and retro-
reflector modules immediately after their installation to the stack or duct. Refer to
Section 2 for the complete installation procedure. Turn on the purge air blowers to
ensure that both the transceiver window
and retroreflector corner cube will be kept
dirt free.
b. Turn on the power source to the intelligent
electronics and connect the HART Communicator per paragraph 3-2. Turn on the
HART Communicator and select CHECK
OPTICS from the DIAG/SERVICE menu.
Next, select the V
menu option to place
STACK
the OPM 2001 in the check optics mode.
c. Align the transceiver and retroreflector.
(Refer to Section 4 for the complete procedure.) If the alignment is performed off of
the stack prior to the installation to meet the
“prior to installation” requirements of 40
CFR, Part 60, Appendix B, Specification 1,
be sure the transceiver and retroreflector
modules are spaced within 1/4 in. (6.35
mm) of the actual installed flange-to-flange
distance. Exit the CHECK OPTICS procedure when alignment is complete.
d. Set up the operating parameters in the
BASIC SETUP and DETAILED SETUP
menus of the HART Communicator. Refer
to paragraphs 3-8 and 3-9 for the complete
setup procedures.
e. Enter the PROCESS VARIABLES menu
and select FLD DEVICE VOLTS per paragraph 3-6a. Four voltages are listed: V
(stack), V
V
(dark). Selecting STACK TEMPERA-
DARK
(lamp), V
LAMP
(ambient), and
AMB
STACK
TURE displays VAD590 (ambient voltage)
and TEMP (transceiver electronics temperature). These voltages and temperature
readings indicate the up-to-date levels of
these measured variables. If the stack or
duct is clear of opacity, the stack voltage
will typically be set at 2.0 volts by the factory. The lamp voltage will typically be set at
4.0 V.
NOTE
The actual ambient conditions at the
installation site may not be the same
as the factory conditions at the time of
testing. Therefore, some variations in
these two voltages will be observed
but will not affect the operation of the
opacity transmitter.
f. View the opacity reading on the HART
Communicator display online menu. Ensure
the primary variable (PV) or the secondary
variable (SV) is set to display opacity. Refer
to paragraph 3-6b. Under clear stack conditions, or with zero jig installed, the opacity
should now read 0.0%. If the opacity reading is other than 0.0 ± 0.5%, recalibrate the
opacity transmitter.
g. Perform an offline calibration per paragraph
3-7b. Reference voltages from the last offline calibration are stored in the REF.
VOLTAGES submenu in the DIAG/
SERVICE menu. This stored data should be
recorded and saved for later reference
before proceeding with another offline
calibration.
Rosemount Analytical Inc. A Division of Emerson Process Management 1-9
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
1-10 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
July 2001
SECTION 2
INSTALLATION
2-2 CHOOSING A LOCATION
Before starting to install this equipment, read the “Safety instructions for
the wiring and installation of this apparatus” at the front of this Instruction
Bulletin. Failure to follow the safety
instructions could result in serious
injury or death.
2-1 GENERAL
Proper functioning of the Rosemount OPM 2001
Opacity/Dust Density Transmitter depends on
proper installation. All procedures in this section
must be followed carefully.
The location of the OPM 2001 is important for
obtaining maximum accuracy in the reading of
the stack particulates. Keep in mind both clearance and process/regulatory considerations
when choosing an installation location.
a. Clearance Considerations
1. Ensure the location is accessible and
provides adequate clearance to service
and maintain the transmitter.
2. Allow 32 in. (813 mm) for clearance on
each side of the stack to remove and
install the weather housings (Figure
2-1).
32 (813) CLEARANCE
NEEDED TO REMOVE
WEATHER HOUSING
(TYP. BOTH SIDES)
CONDUIT TO
INSTRUMENT
NOTES:
1.
SYSTEM TO BE INSTALLED PER LOCAL AND
NATIONAL ELECTRIC CODES.
2.
FOR U.S. APPLICATIONS, REFER TO E.P.A.
INSTALLATION REQUIREMENTS, 40 CFR 60,
APPENDIX B, PERFORMANCE TEST 1.
3.
POWER REQUIREMENTS:
400 WATTS - TRANSCEIVER WITH HEATER
400 WATTS - EACH BLOWER
4.
DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.
5.
CONNECT WIRING/CONDUIT PER NATIONAL
AND LOCAL ELECTRICAL CODE STANDARDS.
ENCLOSURE
PURGE AIR FAILURE
FLOW SWITCH CABLE
(10, FIGURE 1-1)
(SEE NOTE 5)
CUSTOMER-SUPPLIED SIGNAL CABLE
[1 MILE (1.5 KM) MAXIMUM LENGTH]
TO INTELLIGENT
ELECTRONICS
35560027
Figure 2-1. Transmitter Location Considerations
Rosemount Analytical Inc. A Division of Emerson Process Management 2-1
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
3. Locate the transmitter no further than
one mile (1.5 km) from the intelligent
electronics.
b. Regulatory/Process Considerations
The EPA has established the following
guidelines for choosing an opacity/dust
density transmitter installation site:
1. Locate the transmitter across a section
of a duct or stack that will provide a
particulate matter flow through the path
of the transmitter beam representative
of the duct or stack flow.
2. Ensure the transmitter location is downstream from all particulate control
equipment.
3. Locate the transmitter as far from
bends and obstructions as practical.
4. If a transmitter is to be located less
than 4 duct diameters downstream
from a bend, install the transmitter in
the plane defined by the bend. See
Figure 2-2.
5. Ideally, locate the transmitter eight to
ten stack diameters upstream from the
stack exit and three to five diameters
downstream from any bends, junctions,
or other constrictions in the stack or
duct.
For best results, mount the transceiver
and retroreflector modules so the light
beam is exactly perpendicular to the
stack or duct and the beam goes
through the center. Do not install the
transmitter downstream of a wet
scrubber. The water droplets introduced to the gas stream by such
equipment will interfere with the opacity
readings. For an accurate measurement under these conditions, choose a
location upstream from a wet scrubber
or a location downstream from the
scrubber where the water droplets are
vaporized by the reheating of the gas.
2-3 CALIBRATION
The OPM 2001 is factory calibrated for the
flange-to-flange distance (lf) (Figure 1-3) of the
installation site. If the unit needs to be recalibrated, refer to paragraph 3-7b. If a Dust Concentration (DC) output is required after
installation, it is necessary to perform iso-kinetic
sampling on the flue gas while simultaneously
measuring the extinction (E) value. Refer to
paragraph 1-3 for a description of this
procedure.
2-4 MOUNTING FLANGES TO STACK
a. Form two mounting holes in the stack at
locations specified in paragraph 2-2. Holes
must be on the same horizontal and vertical axes. A liquid level can be used to ensure that modules are installed on same
horizontal plane.
b. Install 6 in. pipe and 6 in., 150 lb flanges
following the notes in Figure 2-3. Pipe
Figure 2-2. Transmitter Location
2-2 Rosemount Analytical Inc. A Division of Emerson Process Management
must be horizontal and should protrude at
least 4 to 6 in. (102 to 153 mm).
Model OPM 2001
7/8 (22) DIA. - 8 HOLES
EQUALLY SPACED ON
9-1/2 (241) DIA. B.C.
STRADDLING THE VERTICAL
AND HORIZONTAL CENTERLINES.
11.00
(279) O.D.
FIELD WELD
PIPE TO
FLANGE
Instruction Manual
IB-106-2001 Original Issue
July 2001
OUTSIDE WALL
SURFACE
STUD ANCHORS
3
6
FIELD WELD
PIPE TO
FLANGE AND
METAL STACK
OR DUCT
WALL
6-5/8 (168)
O.D. REF.
3
6.72
(171) I.D.
6 IN. 150 LB R.F. (RAISED FLANGE)
ANSI FLANGE (B16.5)
SUPPLIED BY CUSTOMER
CLEARANCE
NOTES:
DIMENSIONS ARE IN INCHES WITH
1.
MILLIMETERS IN PARENTHESES.
ALL MATERIAL AND FIELD WORK ARE PROVIDED
2.
BY THE CUSTOMER TO INSTALL THE TRANSCEIVER
AND RETROREFLECTOR MODULES OF THE OPACITY
MONITOR.
3.
WHEN FLUE GAS TEMPERATURE IS LESS THAN
600 F (316 C), INSULATE AND LAG THIS AREA TO
°°
PREVENT CONDENSATION AND CORROSION.
4.
A BLANK 11.0 IN. (279 MM) O.D. BLIND 150 LB FLANGE
DRILLED TO A 6.72 IN. (171 MM) I.D. AND DRILLED
AND TAPPED TO 0.75 - 16 UNF (M20) - 8 HOLES
EQUALLY SPACED ON 9.50 IN. (241 MM) DIA. B.C. MAY
BE SUBSTITUTED FOR THE 6 IN. 150 LB RF FLANGE.
Figure 2-3. Stack Flange Installation
c. Weld a flange to each pipe. Align flanges
so that they are relative to a common
centerline. Total module deviation should
not exceed ±5 degrees. Deviation within
this limit can be compensated for by the
air lens ball joint adjustment.
4
4 (102)
MINIMUM
TYPICAL
MASONRY STACK
WALL INSTALLATION
6
6 IN. SCHED. 40
PIPE SUPPLIED
BY CUSTOMER
METAL WALL STACK
OR DUCT INSTALLATION
5.
EXTEND INSULATION ON METAL STACK OR
DUCT SURFACES TO 24 IN. (610 MM). THIS WILL
PREVENT RADIANT HEAT FROM DAMAGING
THE OPACITY MONITOR.
6.
WHEN FLUE GAS TEMPERATURE EXCEEDS 600 F
(316 C), INSERT AN INSULATING GASKET SUCH
°
AS MANUFACTURED BY BNZ MATERIALS, INC.
RECOMMENDED GASKET MATERIAL IS MARINITE
P, AT LEAST 1 IN. (25 MM) THICK. REFER TO
PARAGRAPH 2-7b1 REGARDING THERMO
ISOLATORS.
5
35560022
a. Remove the weather housings by releasing
four toggle clamps (5, Figure 2-4) that hold
each housing to the mounting plate.
b. Remove transceiver optical assembly or ret-
roreflector from air lens assembly (Figures
5-1 and 5-12).
°
2-5 LIFTING AND HANDLING
Use the following procedure to hoist the modules to the installation site and mount them to
the stack:
Rosemount Analytical Inc. A Division of Emerson Process Management 2-3
c. Run a lifting sling through the air lens
opening in the mounting plate (Figure 2-4).
Make sure all hooking devices are secure.
Lift the mounting plate assembly to the installation site.
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
5
2
1
4
3
HANDLING PROCEDURE
TO MOUNT ON STACK, REMOVE WEATHER HOUSING
(1) AND OPTICAL ASSEMBLY (2). LIFT MOUNTING
PLATE ASSEMBLY (3) BY SLING (4) THROUGH THE
AIR WINDOW.
AIR LENS SEAL PLATE (6) MUST REMAIN CLOSED
UNTIL THE BLOWER MOTORS ARE POWERED.
Figure 2-4. Lifting and Handling
2-6 MOUNTING INSTRUCTIONS
6
35560028
2. Make sure heat-resistant gasket (32,
Figure 5-1) is installed between each
module and its stack flange. Attach
each module to the four bolts installed
in each stack flange and secure with
four customer-supplied washers and
nuts.
3. Install stabilizers to provide firm support for each module and secure with
customer-supplied bolts, nuts, and
washers from the inside of the mounting plate (Figure 2-5).
Shutter must remain closed until the
blower is powered up.
4. Close air lens assembly shutter (seal
plate) (6, Figure 2-4) until the blowers
are powered up.
5. Install the transceiver optical assembly
and retroreflector to the mounting
plates and install the weather housings
to the modules (Figure 2-5).
a. Transceiver and Retroreflector Modules
1. Install customer-supplied 0.75-16 bolts
in the stack mounted spool piece and
flange for the mounting plate per Figures 2-3 and 2-5.
b. Intelligent Electronics
The outline drawings in Figure 2-6 show the
mounting centers and clearances for the
two versions of the intelligent electronics.
2-4 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
CUSTOMER-SUPPLIED
STABILIZERS
(2 REQUIRED)
July 2001
TRANSCEIVER
STACK
TYPICAL PLAN VIEW
SQUARE OPENING
(4 PLCS) SPACED
0.88 (22) CLEARANCE
FOR STABILIZERS
4.62 (117)
(SEE NOTE 2)
0.81 (21) DIA.
ON 9.50 (241)
DIA. B.C. (SEE
NOTE 4 AND
NOTE 5)
16.13
(410)
FOR CUSTOMER
HOLES (2 PLCS)
NOTES:
1.
2.
3.
4.
5.
6.
7.
(4 PLCS)HOLES
WIRING
0.81 (21)
CLEARANCE
DIMENSIONS ARE IN INCHES WITH
MILLIMETERS IN PARENTHESES.
MOUNTING PLATE OPENING TO STACK.
FOUR TOGGLE CLAMPS ARE PROVIDED
TO ATTACH MOUNTING PLATE TO
WEATHER HOUSING.
0.75-16 UNF X 3.0 (M20 X 75 MM) HEX HEAD
BOLTS WITH WASHERS AND NUTS
(CUSTOMER-SUPPLIED) REQUIRED TO ATTACH
INSTRUMENT TO 6 IN. 150 LB ANSI FLANGE.
BOLT HOLE PATTERN TO CUSTOMER FLANGE
STRADDLES THE CENTERLINE. MOUNTING
FLANGE AND BOLTS ARE CUSTOMER-SUPPLIED.
SYSTEM TO BE INSTALLED PER LOCAL AND
NATIONAL ELECTRIC CODES.
FOR U.S. APPLICATIONS, REFER TO E.P.A
INSTALLATION REQUIREMENTS, 40CFR60,
APPENDIX B, PERFORMANCE TEST 1.
12.50
(318)
3.50
(89)
7.00
(178)
SECTION A-A
Figure 2-5. Stack Installation Dimensions
RETROREFLECTOR
6.25
(159)
°
22.5
28.77
(731)
22.27
(566)
33.94
(862)
TOGGLE
CLAMP
(SEE NOTE 3)
0.75-16 UNF ANCHOR STUD
STABILIZER
MOUNTING
PLATE
VIEW B
STABILIZER
LENGTH
TO BE 1/8 (0.125)
LESS THAN
DIMENSION X
CUSTOMER-
SUPPLIED MOUNTING
B
(2 REQUIRED)
STACK
SPOOL PIECE
AND FLANGE
X
CUSTOMER-
SUPPLIED
STABILIZERS
A
A
12.50
(318)
4 (102)
MIN. OR
LARGER
AS SPECIFIED
OR INSTALLED
BY CUSTOMER
WIRING
CONDUIT
FLUE
GAS
FLOW
29170009
Rosemount Analytical Inc. A Division of Emerson Process Management 2-5
Instruction Manual
IB-106-2001 Original Issue
July 2001
0.57 (14)
0.177
(4)
5.19 (132)
6.00 (152)
4.71
(120)
5.13
(130)
TYPE 4X INTELLIGENT ELECTRONICSGENERAL PURPOSE INTELLIGENT ELECTRONICS
12.94
(329)
Model OPM 2001
11.00
(279)
8.00
(203)
12.50
(318)
NOTE:
7.00 (178)
DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN PARENTHESES.
Figure 2-6. Intelligent Electronics Mounting Dimensions
2.72
(69)
1.56
LON AND 4-20 mA
(40)
COMMUNICATIONS
4.69
(119)
DIGITAL
INPUT
0.31 (8) x 0.50 (13)
RELAYSPOWER
SLOT
ANALOG
OUTPUTS
29170014
2-6 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
July 2001
1. General Purpose Intelligent Electronics
(a) Install the general purpose intelli-
gent electronics no further than 1
mile (1.5 km) from the stackmounted transceiver unit.
(b) Due to the type of enclosure, the
general purpose unit must be installed indoors where the ambient
temperature is between 40° to
120°F (4° to 50°C).
(c) If mounting the unit on a wall or
bulkhead, use cable clamps and
straps on the wiring as needed to
avoid straining the connections.
2. Type 4X Intelligent Electronics
(a) Mount the Type 4X intelligent
electronics to a wall or bulkhead no
further than 1 mile (1.5 km) from
the stack-mounted transceiver unit.
2-7 MONITORING OPACITY IN HIGH
TEMPERATURE APPLICATIONS
a. Introduction
Measuring opacity in high temperature applications such as incinerators can be detrimental to the physical well-being of opacity
transmitters. Flue gases from incinerators
approach 2000°F (1093°C). Opacity transmitters have reportedly “melted” at these
high temperatures.
Other less severe temperatures just over
400°F (204°C) can also cause opacity
transmitter operation problems. In these
applications, the opacity transmitter is
mounted to a steel duct or steel stack. Radiant heat from the duct or stack can cause
the temperature within the transceiver and
retroreflector modules to exceed ambient
temperature limits.
b. Solution
(b) Locate units without the optional
heater where the ambient temperature is between 40° to 120°F
(4° to 50°C). For units with the optional heater, install where the ambient temperature is between -40°
to 120°F (-40° to 50°C). Keep in
mind that the Type 4X version can
also be installed outdoors.
c. Model 751 Indicator (Optional)
If using the Model 751 indicator, mount in
an accessible location per the instructions in
document PDS 4378A00.
The heat at the opacity transmitter must be
reduced to permit accurate opacity monitoring in these applications. Rosemount
Analytical offers several solutions to help
with these applications.
1. Thermo Isolators. Thermo isolators
should be used whenever the stack
temperature is above 600°F (316°C):
for example, incinerator and hot steel
stack applications. They provide a
heat-resistant barrier between the
stack and opacity transmitter flanges.
Thermo isolators are a must with the
higher temperature incinerators.
Rosemount Analytical Inc. A Division of Emerson Process Management 2-7
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
Rosemount Analytical offers thermo
isolators for the OPM 2001’s 6 in.
mounting flanges. This 1 in. (25.4 mm)
thick high-temperature gasket provides
sufficient thermo isolation to withstand
hot face temperatures of 1700° to
1800°F (927° to 982°C). Two thermo
isolators are required for each OPM
2001. Remember to add 2 in. (51 mm)
to the flange-to-flange dimension (lf)
when thermo isolators are used.
In addition, insulation and a cooling fin
(Figure 2-7) can be installed between
the duct and the opacity transmitter to
INSULATION
STACK
FLANGE
12 IN.
(305 MM)
MINIMUM
ward off radiant heat. This barrier is
recommended for high radiant heat
applications as found in incinerators
and hot steel stacks.
2. Purge Air. A duct or stack maximum
pressure is limited to plus 10 in. WC in
order to supply a minimum flow of
40 SCFM purge air. These constraints
must also be adhered to for this application to be successful. A flow of cool
purge air must be maintained or the
opacity transmitter may suffer heat
damage.
STACK
INSULATION
OPM
2000R
COOLING FIN
INSULATION
4TO6IN.
(102 TO 152 MM)
SIDE VIEW FRONT VIEW
AND HEAT SHIELD
12 IN.
(305 MM)
MINIMUM
Figure 2-7. Insulation and Cooling Fin Installation
35560029
2-8 Rosemount Analytical Inc. A Division of Emerson Process Management
Model OPM 2001
Instruction Manual
IB-106-2001 Original Issue
July 2001
2-8 MONITORING OPACITY AT
LOW AMBIENT TEMPERATURES
a. Introduction
Measuring opacity in locations where ambient temperatures can be expected to go
below -20°F (-28.9°C) can cause false
readings as a result of the extremely cold
ambient air being used by the purge air
blowers. When extremely cold purge air
mixes with the hot process gases, “fogging”
can occur. This phenomenon takes place at
the outlet of the purge air window assembly
and directly in the path of the opacity measurement. As a result, the opacity reading is
falsely represented as a higher than expected value due to the presence of the fog.
b. Solution
The OPM 2001 can be ordered and/or field
retrofitted with purge air heaters. This
heater mounts between the blower and the
purge air window assembly in place of the
check valve and elevates the temperature
of the purge air to prevent fogging. Refer to
Figure 2-8.
2-9 SYSTEM WIRING INSTALLATION
a. Wiring Practices
NOTE
If wiring an OPM 2001 with a general
purpose intelligent electronics, refer to
Figure 2-9. If wiring an OPM 2001 with
a Type 4X intelligent electronics, refer
to Figure 2-10.
b. Transceiver Module
Refer to Figure 2-9 or Figure 2-10 as
appropriate.
1. Make sure communications cable (3,
Figure 5-1) from the transceiver is
plugged into connector J2 on the stack
termination board.
2. Make sure power cable (2, Figure 5-1)
from the transceiver is plugged into
connector J4 on the stack termination
board.
3. Attach the customer-supplied signal
cable to HART and LON connectors J1
and J5 on the stack termination board.
Run the cable through the cable grip in
the mounting plate and tighten the seal
onto the cable.
The wire selected for supplying power to the
intelligent electronics and modules must be
sized to meet the current carrying requirements (capacity) for the application. Refer
to the specifications in paragraph 1-4. The
National Electrical Code contains tables that
may be used as a guide. Voltage classification must be equal to or exceed the rated
circuitry voltage.
All customer-supplied wiring must conform
to standard wiring practices in accordance
with local code. The wire must be able to
withstand the physical stresses to which it
may be subjected during installation.
Rosemount Analytical Inc. A Division of Emerson Process Management 2-9
Check transceiver data plate for the
actual voltage rating. Failure to connect the power cable to the appropriate power source will damage
equipment.
4. Make sure cable (53, Figure 5-1) from
the transceiver purge air failure flow
switch is connected to PR SW 1 connector J7 on the stack termination
board.
Instruction Manual
IB-106-2001 Original Issue
July 2001
Model OPM 2001
5. Attach a line voltage power cable to AC
IN connector J3 on the stack termination board. Run the cable through the
cable grip in the mounting plate.
Tighten the seal onto the cable. Connect the power cable to a suitable line
voltage power source.
NOTES:
1. REMOVE COPPER CHECK VALVE FROM AIR
WINDOW THEN INSTALL HEATER IN SAME
LOCATION.
2. 40 AMP BREAKER REQUIRED.
3. AIR WINDOW ALIGNMENT NUTS MAY NEED TO BE
LOOSENED SO AIR HEATER ASSEMBLY CAN SWING
CLEAR OF OBSTACLES AS IT IS SCREWED INTO AIR
WINDOW.
4. REALIGN TRANSCEIVER AFTER INSTALLATION OF
AIR HEATER.
115 VAC
HEATER
6. Refer to paragraph 3-2 for the procedure to connect the HART communicator to the 4-20 mA signal loop at the
transceiver location.
AIR WINDOW
WHT
BLK
120 VOLT BLOWER
MOTOR JUNCTION
BOX
BLK
GRN
HEATER
GRN
BLU
YEL
WHT
WHT
HEATER
WIRE
WIRE
THERMOSTAT
55 F (13 C) CLOSE
°°
70 F (21 C) OPEN
°°
Figure 2-8. Optional Purge Air Heater
WHT
GRN
BLK
240 VOLT BLOWER
MOTOR JUNCTION
BLK
GRN
WHT
BOX
220 VAC
HEATER
BLU
YEL
35560030
2-10 Rosemount Analytical Inc. A Division of Emerson Process Management
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