Rosemount Manual: OPM3000 Opacity/Dust Density Monitor | Rosemount Manuals & Guides

Instruction Manual Rev 2.0

OPM3000
Opacity/Dust Density Monitor
Installation and Operation Manual Rev 2.0

Instruction Manual Rev B

Table of Contents

TECHNICAL SUPPORT HOTLINE .......................................................................................................................4

SECTION 1 - SYSTEM DESCRIPTION AND SPECIFICATIONS ................................................................................6

PRICIPAL OF OPERATION ...............................................................................................................................................6

TRANSMISSOMETER/RETRO REFLECTOR ..........................................................................................................................7

REMOTE CONTROL UNIT (RCU) ....................................................................................................................................8

Optional Severe Air Purge Weather Cover System ...........................................................................................8

Alignment system ...............................................................................................................................................8

Cabling ................................................................................................................................................................8

OPM3000 OPACITY SPECIFICATIONS ............................................................................................................................9

SECTION 2 INSTALLATION CONSIDERATIONS ................................................................................................ 12

REGULATORY/PROCESS CONSIDERATIONS .................................................................................................................... 12

STACK EXIT CORRELATION COMPUTATIONS .................................................................................................................. 13

Choose an installation site............................................................................................................................... 14

INSTALLATION – MECHANICAL ................................................................................................................................... 15

Installation procedure - stack flanges ............................................................................................................. 15

FLANGE TO STACK INSTALLATION ................................................................................................................................ 17

AIR PURGE/WEATHER COVER MECHANICAL INSTALLATION .............................................................................................. 18

MOUNTING THE AIR PLENUM AND WEATHER COVERS ..................................................................................................... 19

Transceiver and retro reflector assembly ....................................................................................................... 20

SECTION 3 CONTROL UNIT (RCU) OPERATION PAGE DESCRIPTION ................................................................. 21

RCU UNIT BUTTONS ................................................................................................................................................. 21

About page ...................................................................................................................................................... 21

Password protected parameters ..................................................................................................................... 23

SECTION 4 MODBUS ..................................................................................................................................... 25

Modbus Setup ................................................................................................................................................. 25

Modbus Poll ..................................................................................................................................................... 26

RS/485 COMMUNICATIONS AND CONNECTION ............................................................................................................ 27

RS485: Pin out ................................................................................................................................................. 27

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SECTION 5 - OUTPUT CONNECTIONS AND F.S. SETUP .................................................................................... 28

Channel #1 and 2 Full Scale setup ................................................................................................................... 28

Alarm output Connections .............................................................................................................................. 29

GROUP 1 RELAYS ..................................................................................................................................................... 29

GROUP 2 RELAYS ..................................................................................................................................................... 29

ANALOG OUTPUTS 4-20MA ....................................................................................................................................... 30

SECTION 6 – BEAM ALIGNMENT AND CLEAR PATH ADJUSTMENTS ................................................................. 31

BEAM ALIGNMENT PROCEDURE .................................................................................................................................. 31

CLEAR PATH ZERO ADJUSTMENT ................................................................................................................................. 32

Clear path span adjustment ............................................................................................................................ 33

OFF STACK ZERO CALIBRATION ................................................................................................................................... 34

SECTION 7 MICRO-TURN AUDIT KIT .............................................................................................................. 35

USING THE ON LINE ZERO REFLECTOR (OPTION) ............................................................................................................. 35

Procedure ........................................................................................................................................................ 35

Course adjustments ......................................................................................................................................... 36

FILTER CORRECTION FORMULA ................................................................................................................................... 37

Neutral Density Filter certification and standard values ................................................................................. 38

SECTION 8 - PREVENTIVE/CORRECTIVE MAINTENANCE/SPARE PARTS ........................................................... 39

Preventive/corrective maintenance schedule ................................................................................................ 39

Trouble Shooting ............................................................................................................................................. 40

Spare parts ....................................................................................................................................................... 41

SECTION 9 - DRAWINGS................................................................................................................................ 42

Electrical wiring OPM6126 .............................................................................................................................. 43

Mounting stack flanges 38440018 .................................................................................................................. 44

Sensor mounting with or without weather covers 38440021 ........................................................................ 45

RS485: Pin out ................................................................................................................................................. 46

PURGE BLOWER ELECTRICAL AND PRESSURE INFORMATION ............................................................................................. 47

APPENDIX A ................................................................................................................................................. 48

APPENDIX B TO PART 60—PERFORMANCE SPECIFICATIONS ........................................................................................... 48

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Technical Support Hotline

For assistance with problems, please call the Customer Support Center (CSC).

Phone: [phone]

In addition to CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process
Management’s field service throughout the U.S. and abroad.

Phone: [phone]-RMST (1-800-654-7768)

Emerson Process Management may also be reached via the Internet through e-mail and World Wide Web:

e-mail: [e-mail]

World Wide Web: www.raihome.com

World Wide Web: www.raihome.com

Warnings and Safety Guidelines for user safety and equipment protection

This manual is intended to aid trained and competent personnel in the installation of this equipment. Only a technician
or engineer trained in the local and national electrical standards should perform tasks associated with the electrical
wiring of this device.

Warnings

 Under no circumstances will Emerson Process Management be liable or responsible for any consequential

damage that may arise as a result of installation or use of this equipment.

 All examples and diagrams shown in the manual are intended to aid understanding. They do not guarantee

operation.

 Emerson Process Management accepts no responsibility for actual use of this product based on these

examples.

 Due to the great variety of possible applications for this equipment, the user must assess the suitability of this

product for specific applications.

 Make sure to have safety procedures in place to stop any connect3ed equipment in a safe manner if the

controller should malfunction or become damaged for any reason.

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 Do not replace electrical parts or try to repair this product in any way.

 Only qualified factory trained service personnel trained in is operation should open the device’s housing or

carry out repairs.

 The manufacturer is not responsible for problems resulting from improper or irresponsible use of this device.

 You may cause an electric shock, fire or damage the equipment if you ignore any of these safety precautions.

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Instruction Manual Rev B

Section 1 - System Description and Specifications

The OPM3000 Opacity Monitor provides continuous, low maintenance, precision measurement of opacity in industrial
applications. It is a cost-effective instrument that serves as an aid in operating pollution and/or process control
equipment.

Principal of operation

The Dual beam measurement system has a stack mounted Transmissometer sensor system consisting of an
optical transceiver mounted on one side of the stack and a retro reflector mounted on the other. 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 Transmittance 2 (T 2) 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 (T 2)
signal is converted to a current format and sent to the RCU for processing. At the control unit the signal is
processed to read 0-100% Opacity, provide alarms and outputs.

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Transmissometer/retro reflector

The OPM3000 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 reflectors, optical parts and electronics will vary based on path
lengths.

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 temperature 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 OPM3000 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

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 pairs than 20 AWG is acceptable.

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Remote Control Unit (RCU)

The RCU provides instrument control functions, opacity readings, alarms, analog
outputs, communications, system information and more. The RCU can be DIN rail
mounted or panel mounted (3.7x3.7” – 93x93mm) in a control room
environment and is rated NEMA 4X/IP65 when panel mounted. Battery backup
for all memory is typically 7 years.

The control unit should be mounted in a control room environment i.e., clean,
temperature with max/min of +0o to +50 o C (+32 o to + 122 o F). The OPM3000 control
unit provides instrument control functions, opacity readings, alarm and fault
indicators, analog outputs, and diagnostics with contact closures.

Optional Severe 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 three­foot 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 air flow is directed through the hose to an
air plenum on the stack side of the optical window. The air flow 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 OPM3000 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

The standard cabling used between the stack-mounted units and the control unit is at a minimum 6-pair, #20 AWG,
twisted, shielded cable separation distance approximately 1000FT. More pairs or larger than 20 AWG is acceptable.

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Control unit:

Enclosure

Panel mounted IP65/NEMA4X Dimensions 96x96x64

mm (3.8”x3.8’x2.5”). Power 20.4 to 28.8VDC < 10%

ripple, 400mA.

Approvals

CE and UL Listed

Digital Display

Selectable pages, LCD backlight

Ambient Temperature Range

0 to +50o C (+32 to + 122o F)

Power Requirements

24 VDC +/- 10%

Flue Gas Stack/Duct Pressure

+2” (+51mm) Water Column Ma

Alarm Time Delay & set point

6 Relays for alarms

Alarm Reset

Manual or Automatic

Analog Outputs

Two 12-bit Analog outputs 4-20mA, Ch. 1 0-100%
opacity, Ch. 2 mg/m3 selectable ranges.

Maximum range

Opacity 99.9%, 2.0 O.D., 2000mg/m3

Calibration check options

Manual zero and span calibrate with dedicated zero
reflector or Zero with clear stack condition.

Communications

Modbus – RS485 port

Battery Back

7 years typical

OPM3000 Opacity Specifications

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Transceiver/ Reflector:

Enclosure

NEMA 4 watertight enclosure. Power 120/240VAC,
50/60Hz. +/- 10%, Transceiver 65va, Service Module
60va.

Path Length

3 to 40 feet, 0.6 to 4.6 meters.

Optical System

Double Pass

Reflector

Distance dependent

Light Source Aging Compensation

Automatic

Light Source Life

62,000 hours (> 7 years)

Ambient Temperature Limits

-40 to +130o F (-40 to +54o C)

Process Gas

Up to 750o F (400 o C),

Alignment Verification

Built-in through-the-lens system standard

Mounting Flanges

3 inch IPS, 150# flange, standard

Ambient Light Immunity

Solid-state electronic light modulation

Wiring

2 pair twisted shielded cable, 22 AWG

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Design and performance:

Peak and Mean Spectral Response

Photopic; 515 to 585 nm, less than 10% of peak
response outside the desired 400 to 700 nm region.

Angle of View

< 4.0 o from optical axis

Angle of Projection

< 4.0 o 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 Month

Severe Weather Cover with dual blowers:

Material

308 Stainless Steel

Quick release pins

2 for bottom and 2 for top release.

Mounting

3 inch IPS, 150# flange. Others available.

Standard Blower

Single phase, 110/220VAC 50/60Hz

Max stack pressure

+/- 5 inch WC, with the proper installation of purge blowers.

Wind Speed

< 60 mph

Ambient temperature limits

-40oF to 130oF (-4oC to 54oC)

Protection for

Transceiver and Retro-reflector components; purge blowers.

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Section 2 Installation Considerations

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 the figure below.

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. The
stack exit correlation is especially important to verify. If possible
all dimensions should be verified by actual measurements.
Measure and record inside stack dimensions at the measuring
point and at the stack exit, and compute the Optical Path Length
Ratio (O.P.L.R.). Check that the calculated and the O.P.L.R. found
in the Factory OPLR Check step found further in this section are
within +/- 2%.

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Lt

Lx

OPLR*2

50.0

120*2

120

OPLR

Stack Exit Correlation Computations

NOTE: The stack exit correlation is especially important to verify. If possible, all dimensions should be verified
by actual measurements. Using the instructions below verify that the values are correct as displayed in the
about page.
Lx/Lt is the ratio of the inside diameter at the top of the stack to the inside diameter of the stack where the

instrument is located. If the ratio is greater than 1.0, the exit opacity will be greater than the opacity at the
instrument location. The OPM3000 uses this correction factor to calculate the stack exit opacity. It is not
practical to have an Lx/Lt factor much greater than 2.0 because the error of the instrument increases as Lx/Lt
becomes greater.

Lx = inside stack diameter at stack exit.

Lt = inside stack diameter at the transmitter location.

Lf = flange to flange distance between the transceiver and retro reflector unit.

1) Measure and record Lx and Lt and compute the Optical Path Length Ratio (OPLR).

2) Check that the calculated value and the

OPLR found in the 2nd about page are within
±2%.

3) Example: A stack with a 120 in. (3048 mm)

stack exit ID and a 120 in. (3048 m) path
length.

4) Enter the exit diameter (Lx) and measured

diameter (Lt) in the control unit. Refer to
Section 3 for entering the values in the
control unit.

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Choose an installation site

The primary considerations for choosing a site for the OPM3000 are accessibility, ambient environmental
conditions, and locating the unit to obtain a representative sample of the process. Review the excerpt from the
Federal Register in appendix for suggestions before selecting an installation site. The following general
guidelines should also be considered.

Sensors height from Platforms, walk way/ decks, etc, A platform or walkway must be available for access to the
weather covers. The optimum condition would have the mounting flanges and weather covers approximately 5
feet up from the floor. Railings and other obstructions should allow the weather cover to swing clear as shown
in the installation drawings.

Locate the stack-mounted units in an area with ambient temperatures between -4 o to +130o F. (Consult the factory
for other temperature ranges.) Areas that are clean and dry are desirable. Avoid areas with condensation.

Maintenance intervals are directly related to the installation environment. Intervals can vary from 2 to 3 months in
fairly clean environments, to
twice a month in dirty
environments. Lens cleaning is
a function of the ambient
conditions and cleanliness of
the purge air.

Locate the instrument to avoid
excessive vibration or shock.

Locate the control unit in an
easily accessible area with

temperatures between +32o to
122o F. To permit the operator

to read and/or change controls,
the unit should not be mounted
higher than five feet from floor
level.

Stack exit, Locate the transceiver more than two stack diameters down from the stack exit is recommended.

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Installation – Mechanical

A review of the drawings and procedures provided will help to produce an error free installation. However, there are
important additional points that must be observed. The beam of the instrument must be kept in the horizontal plane;

the transceiver cannot be rotated more than +/- 10 o from vertical. The weather covers must be installed vertically
plumb.

Installation and wiring diagrams are
found at the end of this manual. Please
review all drawings prior to starting
installation or wiring. If you have any
questions please contact our Customer
Support Center (CSC) Phone: [phone]­6076 or 1-440-914-1261

E-mail: [e-mail]

Installation procedure - stack
flanges

For an opacity monitor, the customer is
required to supply and install two 3" I.P.S.
flanges at eye level directly across from
each other. The flange faces, mounted on
pipe stubs, should be approximately 6" to
8" from the stack or insulation. On
completion of the installation, the flanges
must be aligned so that the total
deviation of the light source flange
relative to a common centerline, does

not exceed +1o and the retro reflector
flange does not exceed +3o .

Flanges should be mounted approximately 5 feet up from the deck of platforms, roof or walk way.

At installations where conditions permit, this may be accomplished by using a piece of 2 1/2" pipe suspended across
the stack protruding far enough to allow slipping the 3" flange pipe assemblies over each end and welding in place as
shown on the following page.

Any deviation up to the previously specified limits can be adjusted out during the installation and alignment of the light
source and retro reflector with the system's alignment adjustments.

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