Rosemount Manual: OPM 3000 Opacity / Dust Density Monitor-Rev 1.2 | Rosemount Manuals & Guides
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
OPM 3000
Opacity/Dust Density Monitor
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HIGHLIGHTS OF CHANGES
Effective August 31, 2006 Rev 1.0
Page
General
Page 1-1
Page 1-1 thru 1-3
Page1-2 thru 1-3
Page 1-4
Page 1-6 thru 1-7
Page 2-1
Page 2-2
Page 2-3
Page 2-4
Page 2-5 thru 2-6
Page 2-7
Page 2-8
Page 2-9
Page 2-10
Page 2-11
Page 2-12
Page 2-13
Page 2-14
Page 2-15
Page 2-16
Page 3-1
Page 3-2
Page 3-3 thru 3-4 Organized information under First Time Adjustment and Calibration Procedures into
Summary
Revised and removed the figures from Section 8, Drawings, and relocated them in their
applicable sections. Changed all references of the Micro-turn 200 to read as the Zero Jig.
Added information under Component Checklist.
Added General information under System Overview.
Added Figure 1-1, Typical System Package (Sheet 1 and 2).
Added Figure 1-2, Transceiver Assembly with Weather Cover.
Updated Tables 1-1 and 1-2 to represent current conditions.
Added the bulleted list under Overview.
Added Clearance and Sample Area headings along with descriptive text.
Added Figure 2-1, Installation Clearances and Weather Cover Dimensions.
Added information and procedural steps under Regulatory Process Considerations, along
with Figure 2-2, Transmitter Location.
Organized information under Installation of Stack Flanges into procedural steps.
Converted important installation reminders from body text into the five Notes.
Added Figure 2-3, Mounting the Stack Flanges.
Added Figure 2-4, Stack Flange Installation.
Revised and streamlined information for Mounting the Air Plenum and Weather Covers.
Updated Figure 2-6, Air Plenum to better illustrate its assembly. Added Attach Blower
heading and step 1.
Added Note regarding the installation procedures for the transceiver and retro reflector.
Added information and procedural steps under Mounting the Control Unit.
Added Figure 2-8, Mounting Brackets, and Figure 2-9 Control Unit Installation.
Added procedural steps under System Wiring Installation.
Added Figure 2-10, Electrical Installation.
Updated procedural steps under Beam Alignment Procedure. Revised Figure 2-11,
Alignment of the Transceiver.
Moved Output Connections from Section 4.
Added the Caution and information under Overview.
Added Stack Exit Correlation Computation information and Figure 3-1, Lx and Lt Stack
Dimensions.
procedural steps. Revised Figure 3-2, Zero and Span Adjustments to better illustrate the
locations of PT-1 and PT-3.
Page
Page 4-1
Page 4-1 thru 4-3
Page 4-4
Page 5-1 thru 5-6
Page 6-1
Page 6-1 thru 6-2
Page 6-3 thru 6-6
Page 7-1
Page
Cover
Page 1-4
Page 1-5
Page 1-7
Page 2-9
Page 2-10
Page 2-15
Page 5-3
Page 6-6
Page 8-1
Page A-2 thru A-24
Page B-1
Back Cover
HIGHLIGHTS OF CHANGES (CONTINUED)
Effective August 31, 2006 Rev 1.0 (Continued)
Summary
Added bulleted list under Overview.
Organized information under Main Display Screens into procedural steps.
Revised format to display information in procedural steps.
Added Section 5, Zero Jig and Neutral Density Filter.
Added Overview information.
Revised Preventive Maintenance Schedule.
Added Corrective Maintenance procedural steps for the lamp/bulb, transceiver fuse, and
circuit boards. Added Figures 6-1 thru 6-4.
Added Caution, and revised Troubleshooting table to include references.
Effective January, 2007 Rev 1.1
Summary
Added picture of control unit to the cover photo.
Added picture of control unit to Figure 1-2, Transceiver Assembly with Weather Cover.
Revised the TTL Bulls-Eye on Figure 1-3, Component Relationships.
Added Code 03 under Weather Cover and Blowers.
Removed Figure 2-5, Transceiver and Hinge Pins.
Added information on how to attach a single or dual blowers. Added callouts to Figure 2-6,
Air Plenum.
Revised the Beam Alignment Procedure. Replaced Figure 2-11, Alignment of the
Transceiver.
Revised logo on the zero jig, and added the note to Figure 5-2, Zero Jig Installation.
Added the note to Figure 6-4, Power/Modulator Board Replacement.
Revised Section 8, and aded two new spare parts.
Added note 11 to the safety data section. Added new language translations.
Updated the return of materials address.
Updated the address blocks.
Page
Page 2-1
Page 2-2
Page 2-7
Page 2-13
Page 6-2
Effective November, 2007 Rev 1.2
Summary
Added note regarding installed path length.
Clarified transceiver distance from stack exit.
Added note regarding installed path length.
Added information on recommended transceiver to control room cable.
Deleted two year maintenance recommendations.
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
OPM 3000
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1
Description and
Specifications
SECTION 2
Installation
Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OPM 3000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Normal Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Choose an Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Stack Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Regulatory/Process Considerations. . . . . . . . . . . . . . . . . . . . . . . . 2-4
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installation of Stack Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Mounting the Air Plenum and Weather Covers . . . . . . . . . . . . . . . 2-9
Attach Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mounting the Transceiver and Retro Reflector. . . . . . . . . . . . . . . 2-11
Mounting the Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
System Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Beam Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Output Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Channel #1, 0-100% Opacity 4-20 mA Output to
Recording Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Channel #2, 4-20 mA Output to Recording Devices. . . . . . . . . . . 2-16
Alarm Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Early Warning Alarm Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SECTION 3
Startup and Calibration
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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Before Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Startup Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Stack Exit Correlation Computation . . . . . . . . . . . . . . . . . . . . . . . . 3-2
First Time Adjustment and Calibration Procedures . . . . . . . . . . . . . . . 3-3
Clear On Stack Zero and Span Calibration . . . . . . . . . . . . . . . . . . 3-3
OPM 3000
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
SECTION 4
Normal Operation
SECTION 5
Zero Jig and Neutral
Density Filter
SECTION 6
Maintenance
SECTION 7
Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Main Display Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Setup of Password Protected Perimeters. . . . . . . . . . . . . . . . . . . . 4-4
Off Stack Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Zero Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Coarse Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Filter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Filter Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Transceiver Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Circuit Board Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SECTION 8
Spare Parts
APPENDIX A
Safety Data
APPENDIX B
Returning Equipment to
the Factory
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
OPM 3000 Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . 8-1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
TOC-2
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
OPM 3000 Opacity/Dust Density Monitor
OPM 3000
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management 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
Emerson’s 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
Emerson Process Management representative 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 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 to install,
operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
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.
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The information contained in this document is subject to change without
notice.
OPM 3000
:EARTH(GROUND)TERMINAL
:PROTECTIVECONDUCTORTERMINAL
:RISKOFELECTRICAL SHOCK
:WARNING:REFERTOINSTRUCTIONBULLETIN
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
PREFACE
DEFINITIONS
The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the OPM 3000.
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-105-3000, Rev 1.2
November 2007
OPM 3000
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-6
COMPONENT CHECKLIST
SYSTEM OVERVIEW
General
A typical Rosemount Analytical OPM 3000 Opacity/Dust Density Monitor
should contain the items shown in Figure 1-1. Sheet 1 shows the assembly on
the transceiver side, and sheet 2 shows the assembly on the retro reflector
side. Items on the mounting panel are factory installed and come as shown.
Figure 1-2 shows the transceiver assembly with the optional stainless steel
weather cover.
Due to the availability of optional accessories, the system package will vary.
Use the product matrix, in Table 1-2, to compare your order number against
your unit. The first part of the matrix defines the model. The last part defines
the various options and features of the OPM 3000. Ensure the features and
options specified by your order number are on or included with the unit.
The OPM 3000 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.
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.
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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.
OPM 3000
38440032
OPM3000
ESC
Model:
Serial:
A
n
a
l
y
t
i
c
a
l
OPM3000
Opacity/DustDensity
Monitor
InstructionManual
IM-105-3000Rev.1.0
May2006
1
2
3
4 5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
10
1.ControlUnit
2.ZeroJig
3.MountingPlate
4.InstructionManual
5. AirBlower
6. AirFilter
7. AirHosewithClamps
8.Duplexer
9. Transceiverwith
AirPlenumattached
Note: Theoptionalweather
coversarenotshown
inthetypicalsystem
package.
10. TerminalBoard
Figure 1-1. Typical System Package (Sheet 1 of 2)
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
1-2
Instruction Manual
38440041
Model:
Serial:
1
2
Notes: 1.Installairhosefromtheblowerteeon
thetransceiverassembly.
2. Theoptionalweathercoversarenot
showninthetypicalsystempackage.
1.MountingPlate
2.RetroReflectorwith
AirPlenumattached
IM-105-3000, Rev 1.2
November 2007
Figure 1-1. Typical System
Package (Sheet 2 of 2)
OPM 3000
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 transmitter gives accurate, immediate response 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.
OPM 3000 System Features
Transmissometer/Retro Reflector
The OPM 3000 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.
1-3
OPM 3000
38440039
Transceiver
Filter
AirBlower
Mounting
Plate
Duplexer
Weather
Cover
ControlUnit
Figure 1-2. Transceiver
Assembly with Weather Cover
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Control Unit
Mounted in a control room environment, the OPM 3000 control unit provides
instrument control functions (Section 4: Normal Operation for details).
Optional Air Purge Weather Cover System
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 temperatures within the specified ambient
temperatures limits, and errant air currents around the stack.
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.
Alignment System
The OPM 3000 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.
Cabling
1-4
The standard cabling used between the stack-mounted units and the control
unit is at a minimum 2-pair, #22 AWG, twisted, shielded cable. More pairs or
larger than 20 AWG is acceptable.
Instruction Manual
RD MD
ApertureP
MainLamp
TTL Bulls-Eye
ProjectionLens
RetroReflector
ApertureV
38440001
IM-105-3000, Rev 1.2
November 2007
OPM 3000
Normal Mode of Operation
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 1-3). 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
transmittance2 (T2) signal. Because the same light source is used for both
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 (T2) signal is converted to a current format and sent to the control
unit for processing. At the control unit the signal is processed to read 0-100%
opacity, and provide alarms and outputs.
Figure 1-3. Component
Relationships
1-5
OPM 3000
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
SPECIFICATIONS
Table 1-1. OPM 3000
Specifications
Specifications for the OPM 3000 system are listed in Table 1-1.
OPM 3000 Specifications
Control Unit
Enclosure Panel mounted IP65/NEMA 4X Dimensions 3.8 in. x 3.8
in. x 2.5 in. (96 x 96 x 64 mm). Power 20.4 to 28.8VDC
< 10% ripple, 400 mA.
Digital Display LED backlight
Ambient Temperature Range +32 to +122oF (0 to +50oC)
Power Requirements 24 VDC
Alarm Time Delay and Set Point Field programmable, 10 pnp (source) outputs 24 VDC;
Alarm Reset Manual or Automatic
Analog Outputs Two 12-bit Analog outputs: 4-20 mA, 0-10 VDC
OPLR/Exit Correlation
(Lx / 2*Lt)
Calibration Check Options Manual zero and span calibrate with dedicated zero
RS485 Two Ports each Modbus or RS485 networking
I/O Expansion Port Up to 128 additional I/O
Battery Back 7 years typical
Transceiver/Reflector
Enclosure NEMA 4 watertight enclosure. Power 120/240 VAC,
Path Length 3 feet to 53 feet (0.9 to 15.9 meters)
Optical System Double Pass
Reflector Type 1 (plastic) reflector assembly
Light Source Aging
Compensation
Light Source Life 45,000 hours (>5 years)
Ambient Temperature Limits -40 to + 130oF (-40 to +54oC)
Process Gas Up to 750oF (400oC)
Alignment Verification Built-in through-the-lens system standard
Mounting Flanges 3 inch IPS, 150 lb flange, standard
Ambient Light Immunity Solid-state electronic light modulation
Wiring 2 pair twisted shielded cable, 22 AWG
Design and Performance
Peak and Mean Spectral
Response
Angle of View <4.0o from optical axis
Angle of Projection <4.0o from optical axis
Calibration Error <±2% of full scale
Response time <10 second
Zero Drift <1% (24 hours)
Calibration Drift <1% (24 hours)
Operational Period 6 Months
optional relays available.
0.2 to 3.0
reflector or Zero with clear stack condition.
50/60 Hz
Automatic
Photopic; 515 to 585 nm less than 10% of peak
response outside the desired 400 to 700 nm region.
1-6
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Table 1-2. Product Matrix
OPM 3000 OPACITY DUST DENSITY MONITOR - ORDERING INFORMATION
Select complete model number from the Product Matrix
OPM3000 Opacity/Dust Density Monitor Non-compliant
Code Intelligent Electronics
01 Basic Unit – Digital Display, (2) 4-20 mA Outputs, (4) Alarm PNP’s, RS 232/485, Modbus
Code Transceiver and Path Length
11 3-15’ Path Length
12 >15-21’ Path Length
13 >21-40’ Path Length
14 >40-53’ Path Length
Code Weather Cover and Blowers
00 None
01 Weather Covers and Single Blower/Tee
02 Weather Covers Only
03 Weather Covers and Dual Blowers
Code Zero Jig Type
00 None
01 Zero Jig and a 84% Neutral Density Filter
Code Dust Calculation
01 None
02 With Dust Calculation (mg/m3)
OPM3000 01 12 02 00 01 Example
OPM 3000
1-7
OPM 3000
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
1-8
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Section 2 Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . .page 2-2
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5
System Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13
Beam Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . .page 2-15
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 2-16
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 3000
OVERVIEW
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.
NOTE
If installed path length is not within 10% of the factory set path length, return
the unit to the factory so the path length can be reset.
This section describes:
• Considerations prior to installation.
• Mechanical installation procedures, including the applicable drawings
and pictures to assist in the process.
• Wiring schematics for the OPM 3000 system.
• The beam alignment procedure.
• Output connections for alarms and recording devices.
http://www.raihome.com
OPM 3000
INSTALLATION CONSIDERATIONS
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Choose an Installation Site
The primary considerations for choosing a site for the OPM 3000 are
accessibility, ambient environmental conditions, and obtaining a
representative sample of the process. The following general guidelines should
be considered.
Accessibility 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. 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.
Clearance Installation clearances for the transceiver, retro reflector and optional weather
covers are shown in Figure 2-1.
Environment Locate the stack-mounted units in an area with ambient temperatures
between -40
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.
o
to +130oF (-40ο to 54oC). (Consult the factory for other
Choose a location that will minimize excessive vibration or shock.
Locate the control unit in an easily accessible area with temperatures
between +32
change controls, the unit should not be mounted higher than five feet from
floor level.
o
to 122oF (0o to 50oC). To permit the operator to read and/or
Sample Area 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; refer to "Regulatory/Process Considerations". Avoid locations where
large amounts of condensed water is present.
Stack Exit The transceiver should be located a minimum of two stack diameters from the
stack exit. Ideally the transceiver should be installed eight to ten stack
diameters from the stack exit.
2-2
Instruction Manual
38440021
MinimumSwing
Clearance
34in.(863,6mm)
FromFlangeCenter
CoverInUprightPosition
60in.
(1524mm)
21.00in.(533mm)
(2)Covers
GASFLOW
30.5(775mm)
(3)Covers
VERTICAL
AXIS
Leave3in.
(76mm)
clearancefrom
flangeface
forswinging.
StackorBreeching
WallOD
RETRO
TRANSCEIVER
12.250in.
(311mm)
R
6.125in.
(156mm)
6to8in.
(152to203mm)
TOP VIEW*
6to8in.
(152to203mm)
6.125(156mm)
R
7.5in.
(191mm)
SIDEVIEW**
*Note1:
**Note2:
Thetopviewrepresentsthetransceiverandretroreflectorassemblies
withtheirswingclearances.Optionalweathercoversarenotshown.
Thesideviewrepresentstheinstallationandswingclearance
dimensionsfortheoptionalweathercovers.
OptionalWeather
Cover
OptionalWeather
Cover
PLATFORM
PLATFORM
IM-105-3000, Rev 1.2
November 2007
Figure 2-1. Installation Clearances and
Weather Cover Dimensions
OPM 3000
2-3
OPM 3000
Lessthan
4duct
diameters
38440028
Note:
Thetransceiverandretroreflectorareshown
withtheoptionalweathercoversinstalled.
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Regulatory/Process Considerations
The EPA has established the following guidelines for choosing an opacity/dust
density monitor 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 down-stream 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, as
shown in 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 retro reflector 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.
Figure 2-2. Transmitter Location
2-4
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
OPM 3000
MECHANICAL INSTALLATION
Installation of Stack Flanges
NOTE
The beam of the instrument must be kept in a horizontal plane; the transceiver
cannot be rotated more than ±10o from vertical. The weather covers must be
installed vertically level.
Mounting on stack diameters under 6 feet
NOTE
Flanges should be mounted approximately 5 feet (1,5 m) up from the deck of
the platforms, roof or walk way.
1. Form two mounting holes in the stack at locations specified in
"Installation Considerations". Holes must be on the same horizontal and
vertical axes. A liquid level can be used to ensure that modules are
installed on the same horizontal plane.
2. Insert a piece of 2-1/2 in. (64 mm) pipe through the mounting holes.
Make sure pipe is protruding far enough to allow installation of the 3 in.
pipe flange assemblies over each end (Figure 2-3, Stacks Under 6 Feet
Across).
NOTE
The customer is required to supply and install two 3 in. IPS flanges at eye
level directly across from each other.
3. The flanges must be aligned so that the total deviation of the light
source flange relative to a common centerline does not exceed ±1o and
the retro reflector flange does not exceed ±3o. Any deviation within
these limits can be countered during the installation and alignment of
the light source and retro reflector with the system's alignment
adjustments.
4. Weld the pipe flanges to the mounting nipples, as shown in Figure 2-4.
5. Install the pipe flange assemblies into the stack / duct wall. The flange
should be 6 to 8 in. (152 to 203 mm) from the stack or insulation
(Figure 2-4).
Mounting on stack diameters over 6 feet
1. Form two mounting holes in the stack at locations specified in
"Installation Considerations". Holes must be on the same horizontal and
vertical axes. A liquid level can be used to ensure that modules are
installed on the same horizontal plane.
2. Locate one 3-1/2 in. (89 mm) diameter hole (large enough to accept the
3 in. mounting nipple) and the other hole approximately 1/2 in. (13 mm)
diameter, directly across from each other.
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OPM 3000
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
NOTE
An alignment tool can be purchased from the factory to ensure accurate
alignment.
3. Attach the alignment tool to the pipe flange assembly and insert the
assembly into the 3-1/2 in. (89 mm) hole in the stack wall.
4. Align the assembly with the 1/2 in. (13 mm) diameter hole on the
opposite side by viewing through the alignment tool (Figure 2-3, Stacks
Over 6 Feet Across).
5. The flanges must be aligned so that the total deviation of the light
source flange relative to a common centerline does not exceed ±1o and
the retro reflector flange does not exceed ±3o. Any deviation within
these limits can be countered during the installation and alignment of
the light source and retro reflector with the system's alignment
adjustments.
6. Weld the pipe flange to the mounting nipple (Figure 2-4). Care must be
exercised when welding to maintain alignment.
7. Install the pipe flange assembly into the stack/duct wall. The flange
should be 6 to 8 in. (152 to 203 mm) from the stack or insulation
(Figure 2-4).
NOTE
The 1/2 in. (13 mm) diameter hole should now be enlarged to approximately
3-1/2 in. (89 mm) to accept the other flange/pipe assembly.
8. Proceed in the same manner for installation on the opposite side. Install
the other pipe flange assembly with the alignment tool attached, and
secure to the stack/duct wall (Figure 2-4). Maintain concentric alignment
with the pipe flange assembly previously installed on the opposite wall.
2-6
Instruction Manual
6in.-8in.
(152-203mm)
2-1/2in.(64mm)
PipeSizetoSpan
asneeded
(foralignment)
VERTICAL
AXIS
GASFLOW
StackorBreeching
WallOD
3in.Sch40
MountingNipple
38440018
STACKSUNDER6FEET ACROSS
STACKSOVER6FEET ACROSS
Alignment
Tool
½in.(13mm)
AlignmentHole
IM-105-3000, Rev 1.2
November 2007
Figure 2-3. Mounting the
Stack Flanges
OPM 3000
NOTE
If installed path length is not within 10% of the factory set path length, return
the unit to the factory so the path length can be reset.
2-7
OPM 3000
38440029
Stud
Anchors
FieldWeldMounting
NippletoPipeFlange
andMetalStack/
DuctWall
FieldWeld
PipeFlangeto
MountingNipple
7.5in.
(191mm)
6in.(152mm)
BoltCirclle
PIPE
FLANGE
3in.SCH40
MountingNipple
OutsideWall
Surface
OutsideWall
Surface
MASONRY STACK
WALL INSTALLATION
METAL WALL STACK
ORDUCTINSTALLATION
6to8in.
(152-203mm)
Clearance
VERTICAL
AXIS
6to8in.
(152-203mm)
Clearance
Figure 2-4. Stack Flange
Installation
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
2-8
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Mounting the Air Plenum and Weather Covers
OPM 3000
Control unit, transceiver and retro reflector serial numbers must match in order to ensure
accurate measurements.
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 "Installation of Stack Flanges". Flanges should be installed with
the mounting faces on the vertical plane.
NOTE
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 of a chance of damage while
attaching the air plenums and optional weather covers.
1. Verify that the control unit, transceiver and retro reflector serial numbers
match.
2. If an air plenum is attached to either the transceiver or retro reflector,
un-clip the hold-down latche, swing open and lift up and off the hinge
pins (Figure 2-6). Place the transceiver and retro reflector in a safe
place.
3. If the OPM 3000 is equipped with weather covers, remove the two
weather cover hood hinge pins located on the upper right and left hand
corner of the hood.
NOTE
The air plenum and weather cover are attached to the customer supplied 3 in.
pipe flange by four 2-1/2 in. long 5/8-11 bolts.
4. Working from the 3 in. pipe flange, assemble in the following order
(Figure 2-5):
a. gasket
b. mounting plate
c. gasket
d. mating flange and air plenum
5. Place a flat washer onto each of the four 5/8-11 bolts.
6. Once aligned, place the 5/8-11 bolt and flat washer through the top hole
of the middle plate so it is flush against the mating flange.
7. Place a split lock washer over the end of the bolt and secure with a nut.
Repeat for the remaining three mounting bolts.
2-9
OPM 3000
38440003
MiddlePlate
MatingFlange
3”Pipe
Flange
MountingPlate
Gasket
Gasket
5/8-11Bolt(4)
MatingFlangeand
AirPlenum
AirBlowerPort
Mounting
Nipple
Latch
Instruction Manual
IM-105-3000, Rev 1.2
November 2007
Attach Blowers
Figure 2-5. Air Plenum
With Dual Blowers
Connect an air blower to the air blower port on the transceiver using the air
hoses and clamps. Connect the other air blower to the air blower port on the
retro reflector using the air hoses and clamps. See Figure 2-5 for the air
blower port location.
With a Single Blower and Blower Tee
Connect the air blower to the blower tee. Using the air hoses and clamps,
connect the blower tee to the air blower ports on the transceiver and retro
reflector. See Figure 2-5 for the air blower port location.
2-10
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