Rosemount OPM 2000R Transmissometer Opacity / Dust Density Transmitter-Rev 1.1 Manuals & Guides

MODEL OPM 2000R
TRANSMISSOMETER
OPACITY/DUST DENSITY
TRANSMITTER

Instruction Bulletin IB-106-200R Revision 1.1

HIGHLIGHTS OF CHANGES

Effective April, 1998 Rev. 1.0

PAGE SUMMARY

All The revision level changed from Original Issue to Revision 1.0 to distinguish between instruction

bulletins released in a preliminary state and the finalized instruction bulletin.

Effective February, 1999 Rev. 1.1

PAGE SUMMARY

Throughout Changed NEMA 4X to Type 4X.
ii Add electrical symbols.
1-5 Modified the user-definable pathlength range.
2-7 Indicated that power supply 2 (PS2) also supplies power to a status LED. Modified Figure 2-9 to

show that JM1 represents the low gain and JM2 represents the high gain.

2-9 Changed the pathlength range of 20 to 40 ft (6.1 to 12.2 m) to 20 to 26 ft (6.1 to 7.9 m) in

Figure 2-12.
3-1 Illustrated fuse F1 on the IG-1 software board in Figure 3-1.
3-2 Listed relay jumper blocks in paragraph 3-2.b as components on the HART daughter board.

Illustrated fuse F1 on the IG-1 software board in Figure 3-2 and added paragraph 3-2.a.6

discussing the fuse.
3-3 Modified Figure 3-3 to identify the relay jumper blocks and switches. Added paragraph 3-2.b.8 to

discuss the switches.
3-4 Added paragraph 3-2.b.9 to explain the relay jumper blocks.
3-5 Added new Figure 3-4 to illustr ate the HART daughter boa rd relay contact configurations.
3-6 Listed relay jumper blocks in paragraph 3-3.b as components on the HART daughter board.

Updated figure number and figure number references. Illustrated fuse F1 on the IG-1 software

board in Figure 3-5.
3-7 Updated figure numbers and figure number references.
4-0 Added note 5 concerning the purge air failure flow switch cable connection.
4-3 Added the B16.5 designation to the ANSI flange in Figure 4-3.
4-5 Added four holes (and their dimensions) for customer wiring and add ed wiring conduit to

Figure 4-5.
4-8 Added temperatures to Figure 4-8 at which the thermostat opens and closes. Corrected the

specification reference in paragraph 4-9.a.
4-9 Added a no te concerning the relay jumper blocks on the HART da ughter board.
4-10 Added note 1 to Figure 4-9 (Sheet 1 of 2) concerning the transceiver and retroreflector purge air

failure flow switch wiring.

IB-106-200R

HIGHLIGHTS OF CHANGES (Continued)

Effective February, 1999 Rev. 1.1 (Continued)

PAGE SUMMARY

4-12 Added note 1 to Figure 4-10 (Sheet 1 of 2) concerning the transceiver and retroreflector purge air

failure flow switch wiring.

4-13 Modified the HART daughter board to identify the relay jumpers and modified the IG-1 software

board to identify fuse F1 in Figure 4-10 (sheet 2 of 2).
4-14 Added a note concerning the relay jumper blocks on the H ART daughter boar d.
6-9 Added the default setting column to Table 6-6.
6-11 Updated figure reference in paragraph 6-7.b.1.(c). Added new step 6-7.b.3 and modified new

paragraphs 7 and 8 concer ning zero jig usage. Renumbered subsequent steps.
6-12 Added step 6-7.b.12 concerning zero jig usage. Added OCRF information to Table 6-7.
6-15 Changed the number of neutral density filters from 20 to 30.
6-16 Changed the number of neutral density filters from 20 to 30.
6-18 Added a note concerning HART variables assigned the same process variables.
6-19 Added the
6-20 Updated the relay 4 and relay 5 default setting information in Table 6-12.
6-21 Added the default setting column to Table 6-13.
6-23 Added the default setting column to Table 6-15.
6-24 Added the default setting column to Table 6-16.
6-25 Added the default setting column to Table 6-17.
6-26 Added OCRF to the REF. VOLTAGES menu in Figure 6-10 (sheet 1 of 3).
7-5 Added item 12 to Table 7-2 concerning the stack LON board status LED.
8-10 Updated the figure number and item number references in paragraphs 8-5.e.2, 3, and 5.
9-1 Modified the pathlength LF and zero jig ranges in the encode matrix.
9-3 Updated the pathlength LF, zero jig, and certification and labeling portions of the decode matrix.
9-4 Updated the figure number references in Table 9-2.
9-5 Added a second LCW 2 and added descriptive information to the existing LCW 2 in Table 9-4.

Also modified the objective lens and zero jig ranges in Table 9-4 and the retroreflector range in

Table 9-5.
9-6 Updated figure number reference for part number 1A97913H03 in Table 9-6.
C-2 Added OCRF at the end of the REF. VOLTAGES parameter list.

lx/lt

default setting information to paragraph 6-8.c.

IB-106-200R

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon ship­ment, be free of defects in workmanship or material. Should any failure to conform to this
warranty become apparent during a peri od of on e year after the date of s h ipment, Rosemou n t
shall, upon prompt written notice from the purchaser, correct such nonconformity by repair
or replacement, F.O.B. factory of the defective part or parts. Correction in the manner
provided above shall constitute a fulfillment of all liabilities of Rosemount with respect to
the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHER WARRANTIES OF QUALITY WHETHER WRITTEN, ORAL,
OR IMPLIED (INCLUDING ANY WARRANTY OF MERCHANTABILITY OF
FITNESS FOR PURPOSE).

The remedy(ies) provided above s h all be pu rch as er's sole remedy(ies ) f or an y failure of
Rosemount to comply with the warranty provisions, whether claims by the purchaser are
based in contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deteriora tion due to environ­ment. Factors such as corrosive gases and solid particulates can be detrimental and can
create the need for repair or replacement as part of normal wear and tear during the warranty
period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be
subject to the same warran t y as is extended to Rosemoun t by the original manu f actu rer.

At the time of installation it is important that the required services are supplied to the
system and that the electronic controller is set up at least to the point where it is controlling
the sensor heater. This will ensure, that should there be a delay between installation and full
commissioning that the sensor being supplied with ac power and reference air will not be
subjected to component deterioration.

IB-106-200R

i

PURPOSE

The purpose of this manual is to provide a comprehensive understanding of the OPM 2000R
Opacity/Dust Density Transmitter components, function, installation, startup, and maintenance. Opacity
Transmitter and Dust Density Transmitter both refer to the OPM 2000R instrument. The designation for U.S.
applications is Opacity Transmitter and for European applications is Dust Density Transmitter.

The overview presents the basic principles of the Opacity/Dust Density Transmitter along with the
system's performance characteristics and components. The remaining sections contain detailed procedures and
information necessary for the installation , startup, and servicing of the system.

Before contacting Rosemount concerning any questions, first consult this manual. It describes most
situations encountered in your system's operation and details necessary action.

DEFINITIONS

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 essential operating procedure,
condition, or statemen t.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

NOTE

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

.

The number in the low er rig h t corn er of each illu stration in th is pu blication is a manual illustration number.
It is not a part number, and is not related to the illustration in any technical manner.

IB-106-200R

ii

IMPORTANT

SAFETY INSTRUCTIONS FOR THE WIRING AND

INSTALLATION OF THIS APPARATUS

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. Non-EU 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 com pl y with th e requ i rements of IEC227 or IEC245.

4. All wiring sh all be s u itable f or us e 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 mu s t con f orm 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 on ly by trained service pers on n el.

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 IS O3864.

IB-106-200R

iii

BELANGRIJK

Veiligheidsvoorschriften voor de aansluiting en installatie van dit toestel.

De hierna volgende veiligheidsvoorschriften zijn vooral bedoeld voor de EU lidstaten. Hier
moet aan gehouden worden om de onderworpenheid aan de Laag Spannings Richtlijn (Low
Voltage Directive) te verzekeren. Niet EU staten zouden deze richtlijnen moeten volgen
tenzij zij reeds achterhaald zouden zijn door plaatselijke of nationale voorschriften.

1. Degelijke aardingsaansluitingen moeten gemaakt worden naar alle voorziene aardpunten,
intern en extern.

2. Na installatie of controle moeten alle veiligheidsdeksels en -aardingen terug geplaatst
worden. Ten alle tijde moet de betrouwbaarheid van de aarding behouden blijven.

3. Voedingskabels moeten onderworpen zijn aan de IEC227 of de IEC245 voorschriften.

4. Alle bekabeling moet geschikt zijn voor het gebruik in omgevingstemperaturen, hoger dan
75°C.

5. Alle wartels moeten zo gedimensioneerd zijn dat een degelijke kabel bevestiging verzekerd
is.

6. Om de veilige werking van dit toestel te verzekeren, moet de voeding door een
stroomonderbreker gevoerd worden (min 10A) welke alle draden van de voeding moet
onderbreken. De stroomonderbreker mag een mechanische schakelaar bevatten. Zoniet moet
een andere mogelijkheid bestaan om de voedingsspanning van het toestel te halen en ook
duidelijk zo zijn aangegeven. Stroomonderbrekers of schakelaars moeten onderworpen zijn
aan een erkende standaard zoals IEC947.

7. Waar toestellen of deksels aangegeven staan met het symbool is er
meestal hoogspanning aanwezig. Deze deksels mogen enkel verwijderd
worden nadat de voedingsspanning werd afgelegd en enkel door getraind
onderhoudspersoneel.

8. Waar toestellen of deksels aangegeven staan met het symbool is er gevaar
voor hete oppervlakken. Deze deksels mogen enkel verwijderd worden
door getraind onderhoudspersoneel nadat de voedingsspanning
verwijderd werd. Sommige oppper-vlakken kunnen 45 minuten later nog
steeds heet aanvoelen.

9. Waar toestellen of deksels aangegeven staan met het symbool gelieve het
handboek te raadplegen.

10. Alle grafische symbolen gebruikt in dit produkt, zijn afkomstig uit een of meer van
devolgende standaards: EN61010-1, IEC417 en ISO3864.

IB-106-200R

iv

VIGTIGT

Sikkerhedsinstruktion for tilslutning og installering af dette udstyr.

Følgende sikkerhedsinstruktioner gælder specifikt i alle EU-medlemslande.
Instruktionerne skal nøje følges for overholdelse af Lavsspændingsdirektivet og bør også
følges i ikke EU-lande medmindre andet er specificeret af lokale eller nationale standarder.

1. Passende jordforbindelser skal tilsluttes alle jordklemmer, interne og eksterne, hvor disse
forefindes.

2. Efter installation eller fejlfinding skal alle sikkerhedsdæksler og jordforbindelser
reetableres.

3. Forsyningskabler skal opfylde krav specificeret i IEC227 eller IEC245.

4. Alle ledningstilslutninger skal være konstrueret til omgivelsestemperatur højere end 75° C.

5. Alle benyttede kabelforskruninger skal have en intern dimension, så passende
kabelaflastning kan etableres.

6. For opnåelse af sikker drift og betjening skal der skabes beskyttelse mod indirekte berøring
gennem afbryder (min. 10A), som vil afbryde alle kredsløb med elektriske ledere i fejlsitua­tion. Afbryderen skal indholde en mekanisk betjent kontakt. Hvis ikke skal anden form for
afbryder mellem forsyning og udstyr benyttes og mærkes som sådan. Afbrydere eller
kontakter skal overholde en kendt standard som IEC947.

7. Hvor udstyr eller dæksler er mærket med dette symbol, er farlige spændinger
normalt forekom-mende bagved. Disse dæksler bør kun afmonteres, når
forsyningsspændingen er frakoblet - og da kun af instrueret servicepersonale.

8. Hvor udstyr eller dæksler er mærket med dette symbol, forefindes meget
varme overflader bagved. Disse dæksler bør kun afmonteres af instrueret
servicepersonale, når forsyningsspænding er frakoblet. Visse overflader vil
stadig være for varme at berøre i op til 45 minutter efter frakobling.

9. Hvor udstyr eller dæksler er mærket med dette symbol, se da i
betjeningsmanual for instruktion.

10. Alle benyttede grafiske symboler i dette udstyr findes i én eller flere af følgende standarder:­EN61010-1, IEC417 & ISO3864.

IB-106-200R

v

BELANGRIJK

Veiligheidsinstructies voor de bedrading en installatie van dit apparaat.

Voor alle EU lidstaten zijn de volgende veiligheidsinstructies van toepassing. Om aan de
geldende richtlijnen voor laagspanning te voldoen dient men zich hieraan strikt te houden.
Ook niet EU lidstaten dienen zich aan het volgende te houden, tenzij de lokale wetgeving
anders voorschrijft.

1. Alle voorziene interne- en externe aardaansluitingen dienen op adequate wijze aangesloten
te worden.

2. Na installatie,onderhouds- of reparatie werkzaamheden dienen alle beschermdeksels
/kappen en aardingen om reden van veiligheid weer aangebracht te worden.

3. Voedingskabels dienen te voldoen aan de vereisten van de normen IEC 227 of IEC 245.

4. Alle bedrading dient geschikt te zijn voor gebruik bij een omgevings temperatuur boven
75°C.

5. Alle gebruikte kabelwartels dienen dusdanige inwendige afmetingen te hebben dat een
adequate verankering van de kabel wordt verkregen.

6. Om een veilige werking van de apparatuur te waarborgen dient de voeding uitsluitend plaats
te vinden via een meerpolige automatische zekering (min.10A) die

alle

spanningvoerende
geleiders verbreekt indien een foutconditie optreedt. Deze automatische zekering mag ook
voorzien zijn van een mechanisch bediende schakelaar. Bij het ontbreken van deze
voorziening dient een andere als zodanig duidelijk aangegeven mogelijkheid aanwezig te
zijn om de spanning van de apparatuur af te schakelen. Zekeringen en schakelaars dienen te
voldoen aan een erkende standaard zoals IEC 947.

7. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het
volgende symbool, kunnen zich hieronder spanning voerende delen bevinden
die gevaar op kunnen leveren. Deze beschermdeksels/kappen mogen
uitsluitend verwijderd worden door getraind personeel als de spanning is
afgeschakeld.

8. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het
volgende symbool, kunnen zich hieronder hete oppervlakken of onderdelen
bevinden. Bepaalde delen kunnen mogelijk na 45 min. nog te heet zijn om aan
te raken.

9. Waar de apparatuur of de beschermdeksels/kappen gemarkeerd zijn met het
volgende symbool, dient men de bedieningshandleiding te raadplegen.

10. Alle grafische symbolen gebruikt bij dit produkt zijn volgens een of meer van de volgende
standaarden: EN 61010-1, IEC 417 & ISO 3864.

IB-106-200R

vi

TÄRKEÄÄ

Turvallisuusohje, jota on noudatettava tämän laitteen asentamisessa ja kaapeloinnissa.

Seuraavat ohjeet pätevät erityisesti EU:n jäsenvaltioissa. Niitä täytyy ehdottomasti
noudattaa jotta täytettäisiin EU:n matalajännitedirektiivin (Low Voltage Directive)
yhteensopivuus. Myös EU:hun kuulumattomien valtioiden tulee nou-dattaa tätä ohjetta,
elleivät kansalliset standardit estä sitä.

1. Riittävät maadoituskytkennät on tehtävä kaikkiin maadoituspisteisiin, sisäisiin ja ulkoisiin.

2. Asennuksen ja vianetsinnän jälkeen on kaikki suojat ja suojamaat asennettava takaisin pai­koilleen. Maadoitusliittimen kunnollinen toiminta täytyy aina ylläpitää.

3. Jännitesyöttöjohtimien täytyy täyttää IEC227 ja IEC245 vaatimukset.

4. Kaikkien johdotuksien tulee toimia >75°C lämpötiloissa.

5. Kaikkien läpivientiholkkien sisähalkaisijan täytyy olla sellainen että kaapeli lukkiutuu kun­nolla kiinni.

6. Turvallisen toiminnan varmistamiseksi täytyy jännitesyöttö varustaa turvakytkimellä (min
10A), joka kytkee irti kaikki jännitesyöttöjohtimet vikatilanteessa. Suojaan täytyy myös
sisältyä mekaaninen erotuskytkin. Jos ei, niin jännitesyöttö on pystyttävä katkaisemaan
muilla keinoilla ja merkittävä siten että se tunnistetaan sellaiseksi. Turvakytkimien tai kat­kaisimien täytyy täyttää IEC947 standardin vaatimukset näkyvyydestä.

7. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän
takana tai alla hengenvaarallisen suuruinen jännite. Suojaa ei saa poistaa
jänniteen ollessa kytkettynä laitteeseen ja poistamisen saa suorittaa vain
alan asian-tuntija.

8. Mikäli laite tai kosketussuoja on merkitty tällä merkillä on merkinnän
takana tai alla kuuma pinta. Suojan saa poistaa vain alan asiantuntija kun
jännite-syöttö on katkaistu. Tällainen pinta voi säilyä kosketuskuumana
jopa 45 mi-nuuttia.

9. Mikäli laite tai kosketussuoja on merkitty tällä merkillä katso lisäohjeita
käyt-töohjekirjasta

10. Kaikki tässä tuotteessa käytetyt graafiset symbolit ovat yhdestä tai useammasta seuraavis-ta
standardeista: EN61010-1, IEC417 & ISO3864.

IB-106-200R

vii

IMPORTANT

Consignes de sécurité concernant le raccordement et l’installation de cet appareil.

Les consignes de sécurité ci-dessous s’adressent particulièrement à tous les états membres
de la communauté européenne. Elles doivent être strictement appliquées afin de satisfaire
aux directives concernant la basse tension. Les états non membres de la communauté
européenne doivent également appliquer ces consignes sauf si elles sont en contradiction
avec les standards locaux ou nationaux.

1. Un raccordement adéquat à la terre doit être effectuée à chaque borne de mise à la terre,
interne et externe.

2. Après installation ou dépannage, tous les capots de protection et toutes les prises de terre
doivent être remis en place, toutes les prises de terre doivent être respectées en permanence.

3. Les câbles d’alimentation électrique doivent être conformes aux normes IEC227 ou IEC245

4. Tous les raccordements doivent pouvoir supporter une température ambiante supérieure à
75°C.

5. Tous les presse-étoupes utilisés doivent avoir un diamètre interne en rapport avec les câbles
afin d’assurer un serrage correct sur ces derniers.

6. Afin de garantir la sécurité du fonctionnement de cet appareil, le raccordement à
l’alimentation électrique doit être réalisé exclusivement au travers d’un disjoncteur
(minimum 10A.) isolant tous les conducteurs en cas d’anomalie. Ce disjoncteur doit
également pouvoir être actionné manuellement, de façon mécanique. Dans le cas contraire,
un autre système doit être mis en place afin de pouvoir isoler l’appareil et doit être signalisé
comme tel. Disjoncteurs et interrupteurs doivent être conformes à une norme reconnue telle
IEC947.

7. Lorsque les équipements ou les capots affichent le symbole suivant, cela
signifie que des tensions dangereuses sont présentes. Ces capots ne doivent
être démontés que lorsque l’alimentation est coupée, et uniquement par un
personnel compétent.

8. Lorsque les équipements ou les capots affichent le symbole suivant, cela
signifie que des surfaces dangereusement chaudes sont présentes. Ces capots
ne doivent être démontés que lorsque l’alimentation est coupée, et uniquement
par un personnel compétent. Certaines surfaces peuvent rester chaudes jusqu’à
45 mn.

9. Lorsque les équipements ou les capots affichent le symbole suivant, se
reporter au manuel d’instructions.

10. Tous les symboles graphiques utilisés dans ce produit sont conformes à un ou plusieurs des
standards suivants: EN61010-1, IEC417 & ISO3864.

IB-106-200R

viii

Wichtig

Sicherheitshinweise für den Anschluß und die Installation dieser Geräte.

Die folgenden Sicherheitshinweise sind in allen Mitgliederstaaten der europäischen
Gemeinschaft gültig. Sie müssen strickt eingehalten werden, um der
Niederspannungsrichtlinie zu genügen. Nichtmitgliedsstaaten der europäischen
Gemeinschaft sollten die national gültigen Normen und Richtlinien einhalten.

1. Alle intern und extern vorgesehenen Erdungen der Geräte müssen ausgeführt werden.

2. Nach Installation, Reparatur oder sonstigen Eingriffen in das Gerät müssen alle
Sicherheitsabdeckungen und Erdungen wieder installiert werden. Die Funktion aller
Erdverbindungen darf zu keinem Zeitpunkt gestört sein.

3. Die Netzspannungsversorgung muß den Anforderungen der IEC227 oder IEC245 genügen.

4. Alle Verdrahtungen sollten mindestens bis 75 °C ihre Funktion dauerhaft erfüllen.

5. Alle Kabeldurchführungen und Kabelverschraubungen sollten in Ihrer Dimensionierung so
gewählt werden, daß diese eine sichere Verkabelung des Gerätes ermöglichen.

6. Um eine sichere Funktion des Gerätes zu gewährleisten, muß die Spannungsversorgung über
mindestens 10 A abgesichert sein. Im Fehlerfall muß dadurch gewährleistet sein, daß die
Spannungsversorgung zum Gerät bzw. zu den Geräten unterbrochen wird. Ein mechanischer
Schutzschalter kann in dieses System integriert werden. Falls eine derartige Vorrichtung
nicht vorhanden ist, muß eine andere Möglichkeit zur Unterbrechung der Spannungszufuhr
gewährleistet werden mit Hinweisen deutlich gekennzeichnet werden. Ein solcher
Mechanismus zur Spannungsunterbrechung muß mit den Normen und Richtlinien für die
allgemeine Installation von Elektrogeräten, wie zum Beispiel der IEC947, übereinstimmen.

7. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, die eine
gefährliche (Netzspannung) Spannung führen. Die Abdeckungen dürfen
nur entfernt werden, wenn die Versorgungsspannung unterbrochen wurde.
Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen.

8. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, in bzw.
unter denen heiße Teile vorhanden sind. Die Abdeckungen dürfen nur
entfernt werden, wenn die Versorgungsspannung unterbrochen wurde.
Nur geschultes Personal darf an diesen Geräten Arbeiten ausführen. Bis
45 Minuten nach dem Unterbrechen der Netzzufuhr können derartig Teile
noch über eine erhöhte Temperatur verfügen.

9. Mit dem Symbol sind Geräte oder Abdeckungen gekennzeichnet, bei
denen vor dem Eingriff die entsprechenden Kapitel im Handbuch
sorgfältig durchgelesen werden müssen.

10. Alle in diesem Gerät verwendeten graphischen Symbole entspringen einem oder mehreren
der nachfolgend aufgeführten Standards: EN61010-1, IEC417 & ISO3864.

IB-106-200R

ix

IMPORTANTE

Norme di sicurezza per il cablaggio e l’installazione dello strumento.

Le seguenti norme di sicurezza si applicano specificatamente agli stati membri dell’Unione
Europea, la cui stretta osservanza è richiesta per garantire conformità alla Direttiva del
Basso Voltaggio. Esse si applicano anche agli stati non appartenenti all’Unione Europea,
salvo quanto disposto dalle vigenti normative locali o nazionali

1. Collegamenti di terra idonei devono essere eseguiti per tutti i punti di messa a terra interni
ed esterni, dove previsti.

2. Dopo l’installazione o la localizzazione dei guasti, assicurarsi che tutti i coperchi di
protezione siano stati collocati e le messa a terra siano collegate. L’integrità di ciscun
morsetto di terra deve essere costantemente garantita.

3. I cavi di alimentazione della rete devono essere secondo disposizioni IEC227 o IEC245.

4. L’intero impianto elettrico deve essere adatto per uso in ambiente con temperature superiore
a 75°C.

5. Le dimensioni di tutti i connettori dei cavi utilizzati devono essere tali da consentire un
adeguato ancoraggio al cavo.

.

6. Per garantire un sicuro funzionamento dello strumento il collegamento alla rete di
alimentazione principale dovrà essere eseguita tramite interruttore automatico (min.10A), in
grado di disattivare tutti i conduttori di circuito in caso di guasto. Tale interruttore dovrà
inoltre prevedere un sezionatore manuale o altro dispositivo di interruzione
dell’alimentazione, chiaramente identificabile. Gli interruttori dovranno essere conformi
agli standard riconosciuti, quali IEC947.

7. Il simbolo riportato sullo strumento o sui coperchi di protezione indica
probabile presenza di elevati voltaggi. Tali coperchi di protezione devono
essere rimossi esclusivamente da personale qualificato, dopo aver tolto
alimentazione allo strumento.

8. Il simbolo riportato sullo strumento o sui coperchi di protezione indica rischio
di contatto con superfici ad alta temperatura. Tali coperchi di protezione
devono essere rimossi esclusivamente da personale qualificato, dopo aver tolto
alimentazione allo strumento. Alcune superfici possono mantenere
temperature elevate per oltre 45 minuti.

9. Se lo strumento o il coperchio di protezione riportano
il simbolo, fare riferimento alle istruzioni del manuale
Operatore.

10. Tutti i simboli grafici utilizzati in questo prodotto sono previsti da uno o più dei seguenti
standard: EN61010-1, IEC417 e ISO3864.

IB-106-200R

x

VIKTIG

Sikkerhetsinstruks for tilkobling og installasjon av dette utstyret.

Følgende sikkerhetsinstruksjoner gjelder spesifikt alle EU medlemsland og land med i
EØS-avtalen. Instruksjonene skal følges nøye slik at installasjonen blir i henhold til
lavspenningsdirektivet. Den bør også følges i andre land, med mindre annet er spesifisert
av lokale- eller nasjonale standarder.

1. Passende jordforbindelser må tilkobles alle jordingspunkter, interne og eksterne hvor disse
forefinnes.

2. Etter installasjon eller feilsøking skal alle sikkerhetsdeksler og jordforbindelser reetableres.
Jordingsforbindelsene må alltid holdes i god stand.

3. Kabler fra spenningsforsyning skal oppfylle kravene spesifisert i IEC227 eller IEC245.

4. Alle ledningsforbindelser skal være konstruert for en omgivelsestemperatur høyere en 750C.

5. Alle kabelforskruvninger som benyttes skal ha en indre dimensjon slik at tilstrekkelig
avlastning oppnåes.

6. For å oppnå sikker drift og betjening skal forbindelsen til spenningsforsyningen bare skje
gjennom en strømbryter (minimum 10A) som vil bryte spenningsforsyningen til alle
elektriske kretser ved en feilsituasjon. Strømbryteren kan også inneholde en mekanisk
operert bryter for å isolere instrumentet fra spenningsforsyningen. Dersom det ikke er en
mekanisk operert bryter installert, må det være en annen måte å isolere utstyret fra
spenningsforsyningen, og denne måten må være tydelig merket. Kretsbrytere eller
kontakter skal oppfylle kravene i en annerkjent standard av typen IEC947 eller tilsvarende.

7. Der hvor utstyr eller deksler er merket med symbol for farlig spenning, er det
sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare fjærnes når
spenningsforsyning er frakoblet utstyret, og da bare av trenet servicepersonell.

8. Der hvor utstyr eller deksler er merket med symbol for meget varm overflate,
er det sannsynlig at disse er tilstede bak dekslet. Disse dekslene må bare
fjærnes når spenningsforsyning er frakoblet utstyret, og da bare av trenet
servicepersonell. Noen overflater kan være for varme til å berøres i opp til 45
minutter etter spenningsforsyning frakoblet.

9. Der hvor utstyret eller deksler er merket med symbol, vennligst referer til
instruksjonsmanualen for instrukser.

10. Alle grafiske symboler brukt i dette produktet er fra en eller flere av følgende standarder:
EN61010-1, IEC417 & ISO3864.

IB-106-200R

xi

IMPORTANTE

Instruções de segurança para ligação e instalação deste aparelho.

As seguintes instruções de segurança aplicam-se especificamente a todos os estados
membros da UE. Devem ser observadas rigidamente por forma a garantir o cumprimento
da Directiva sobre Baixa Tensão. Relativamente aos estados que não pertençam à UE,
deverão cumprir igualmente a referida directiva, exceptuando os casos em que a legislação
local a tiver substituído.

1. Devem ser feitas ligações de terra apropriadas a todos os pontos de terra, internos ou externos.

2. Após a instalação ou eventual reparação, devem ser recolocadas todas as tampas de seg urança
e terras de protecção. Deve manter-se sempre a integridade de todos os terminais de terra.

3. Os cabos de alimentação eléctrica devem obedecer às exigências das normas IEC227 ou
IEC245.

4. Os cabos e fios utilizados nas ligações eléctricas devem ser adequados para utilização a uma
temperatura ambiente até 75º C.

5. As dimensões internas dos bucins dos cabos devem ser adequadas a uma boa fixação dos
cabos.

6. Para assegurar um funcionamento seguro deste equipamento, a ligação ao cabo de
alimentação eléctrica deve ser feita através de um disjuntor (min. 10A) que desligará todos
os condutores de circuitos durante uma avaria. O disjuntor poderá também conter um
interruptor de isolamento accionado manualmente. Caso contrário, deverá ser instalado
qualquer outro meio para desligar o equipamento da energia eléctrica, devendo ser
assinalado convenientemente. Os disjuntores ou interruptores devem obedecer a uma norma
reconhecida, tipo IEC947.

7. Sempre que o equipamento ou as tampas contiverem o símbolo, é provável a
existência de tensões perigosas. Estas tampas só devem ser retiradas quando a
energia eléctrica tiver sido desligada e por Pessoal da Assistência devidamente
treinado.

8. Sempre que o equipamento ou as tampas contiverem o símbolo, há perigo de
existência de superfícies quentes. Estas tampas só devem ser retiradas por
Pessoal da Assistência devidamente treinado e depois de a energia eléctrica ter
sido desligada. Algumas superfícies permanecem quentes até 45 minutos
depois.

9. Sempre que o equipamento ou as tampas contiverem o símbolo, o Manual de
Funcionamento deve ser consultado para obtenção das necessárias instruções.

10. Todos os símbolos gráficos utilizados neste produto baseiam-se em uma ou mais das
seguintes normas: EN61010-1, IEC417 e ISO3864.

IB-106-200R

xii

IMPORTANTE

Instrucciones de seguridad para el montaje y cableado de este aparato.

Las siguientes instrucciones de seguridad , son de aplicacion especifica a todos los
miembros de la UE y se adjuntaran para cumplir la normativa europea de baja tension.

1. Se deben preveer conexiones a tierra del equipo, tanto externa como internamente, en
aquellos terminales previstos al efecto.

2. Una vez finalizada las operaciones de mantenimiento del equipo, se deben volver a colocar
las cubiertas de seguridad aasi como los terminales de tierra. Se debe comprobar la
integridad de cada terminal.

3. Los cables de alimentacion electrica cumpliran con las normas IEC 227 o IEC 245.

4. Todo el cableado sera adecuado para una temperatura ambiental de 75ºC.

5. Todos los prensaestopas seran adecuados para una fijacion adecuada de los cables.

6. Para un manejo seguro del equipo, la alimentacion electrica se realizara a traves de un
interruptor magnetotermico ( min 10 A ), el cual desconectara la alimentacion electrica al
equipo en todas sus fases durante un fallo. Los interruptores estaran de acuerdo a la norma
IEC 947 u otra de reconocido prestigio.

7. Cuando las tapas o el equipo lleve impreso el simbolo de tension electrica
peligrosa, dicho alojamiento solamente se abrira una vez que se haya
interrumpido la alimentacion electrica al equipo asimismo la intervencion
sera llevada a cabo por personal entrenado para estas labores.

8. Cuando las tapas o el equipo lleve impreso el simbolo, hay superficies
con alta temperatura, por tanto se abrira una vez que se haya interrumpido
la alimentacion electrica al equipo por personal entrenado para estas
labores, y al menos se esperara unos 45 minutos para enfriar las
superficies calientes.

9. Cuando el equipo o la tapa lleve impreso el simbolo, se consultara el
manual de instrucciones.

10. Todos los simbolos graficos usados en esta hoja, estan de acuerdo a las siguientes normas
EN61010-1, IEC417 & ISO 3864.

IB-106-200R

xiii

VIKTIGT

Säkerhetsföreskrifter för kablage och installation av denna apparat.

Följande säkerhetsföreskrifter är tillämpliga för samtliga EU-medlemsländer. De skall
följas i varje avseende för att överensstämma med Lågspännings direktivet. Icke EU
medlemsländer skall också följa nedanstående punkter, såvida de inte övergrips av lokala
eller nationella föreskrifter.

1. Tillämplig jordkontakt skall utföras till alla jordade punkter, såväl internt som externt där så
erfordras.

2. Efter installation eller felsökning skall samtliga säkerhetshöljen och säkerhetsjord
återplaceras. Samtliga jordterminaler måste hållas obrutna hela tiden.

3. Matningsspänningens kabel måste överensstämma med föreskrifterna i IEC227 eller
IEC245.

4. Allt kablage skall vara lämpligt för användning i en omgivningstemperatur högre än 75ºC.

5. Alla kabelförskruvningar som används skall ha inre dimensioner som motsvarar adekvat
kabelförankring.

6. För att säkerställa säker drift av denna utrustning skall anslutning till huvudströmmen endast
göras genom en säkring (min 10A) som skall frånkoppla alla strömförande kretsar när något
fel uppstår. Säkringen kan även ha en mekanisk frånskiljare. Om så inte är fallet, måste ett
annat förfarande för att frånskilja utrustningen från strömförsörjning tillhandahållas och
klart framgå genom markering. Säkring eller omkopplare måste överensstämma med en
gällande standard såsom t ex IEC947.

7. Där utrustning eller hölje är markerad med vidstående symbol föreliggerisk för
livsfarlig spänning i närheten. Dessa höljen får endast avlägsnas när strömmen
ej är ansluten till utrustningen - och då endast av utbildad servicepersonal.

8. När utrustning eller hölje är markerad med vidstående symbol föreligger risk
för brännskada vid kontakt med uppvärmd yta. Dessa höljen får endast
avlägsnas av utbildad servicepersonal, när strömmen kopplats från
utrustningen. Vissa ytor kan vara mycket varma att vidröra även upp till 45
minuter efter avstängning av strömmen.

9. När utrustning eller hölje markerats med vidstående symbol bör
instruktionsmanualen studeras för information.

10.

Samtliga grafiska symboler som förekommer i denna produkt finns angivna i en eller flera
av följande föreskrifter:- EN61010-1, IEC417 & ISO3864.

IB-106-200R

xiv

IB-106-200R

xv/xvi

TABLE OF CONTENTS

Section Page

Rosemount Warranty.......................................................................................................................... i

Purpose............................................................................................................................................... ii

I. SYSTEM OVERVIEW

1-1. Component Checklist of Typical System (Package Contents)................................... 1-1

1-2. System Overview....................................................................................................... 1-1

1-3. Method of Measurement............................................................................................ 1-4

1-4. Specifications ............................................................................................................ 1-5

1-5. System Startup Procedure.......................................................................................... 1-7

II. TRANSCEIVER AND RETROREFLECTOR MODULES

2-1. Transceiver Module................................................................................................... 2-1

2-2. Retroreflector Module............................................................................................... 2-9

2-3. Purge Air Failure Flow Switch.................................................................................. 2-9

2-4. Air Lens Assembly.................................................................................................... 2-10

III. INTELLIGENT ELECTRONICS

3-1. General...................................................................................................................... 3-1

3-2. Intelligent Electronics (General Purpose).................................................................. 3-1

3-3. Type 4X Intelligent Electronics (Option).................................................................. 3-6

IV. INSTALLATION

4-1. General...................................................................................................................... 4-1

4-2. Choosing a Location.................................................................................................. 4-1

4-3. Calibration.................................................................................................................4-2

4-4. Mounting Flanges to Stack........................................................................................ 4-2

4-5. Lifting and Handling.................................................................................................. 4-4

4-6. Mounting Instructions................................................................................................ 4-4

4-7. Monitoring Opacity in High Temperature Applications............................................ 4-7

4-8. Monitoring Opacity at Low Ambient Temperatures.................................................. 4-8

4-9. System Wiring Installation ........................................................................................ 4-8

V. ALIGNMENT

5-1. Optical Alignment..................................................................................................... 5-1

5-2. Objective Lens Adjustment ....................................................................................... 5-3

VI. OPERATION

6-1. Overview................................................................................................................... 6-1

6-2. HART Communicator Signal Line Connections........................................................ 6-1

6-3. Offline and Online Operations................................................................................... 6-5

6-4. HART Operator Interface Description...................................................................... 6-5

6-5. Using the HART Interface......................................................................................... 6-7

6-6. PROCESS VARIABLES Menu................................................................................ 6-8

6-7. DIAG/SERVICE Menu............................................................................................. 6-10

6-8. BASIC SETUP Menu................................................................................................ 6-17

6-9. DETAILED SETUP Menu........................................................................................ 6-20

6-10. REVIEW Menu......................................................................................................... 6-25

6-11. HART Communicator Menu Tree for OPM 2000R.................................................. 6-25

IB-106-200R

xvii

TABLE OF CONTENTS (Continued)

Section Page

VII. TROUBLESHOOTING

7-1. General....................................................................................................................... 7-1

7-2. System Mode Indicators ............................................................................................ 7-1

7-3. Diagnostics ................................................................................................................ 7-1

7-4. Test Procedures.......................................................................................................... 7-6

VIII. SERVICE AND NORMAL MAINTENANCE

8-1. General....................................................................................................................... 8-1

8-2. Preventive Maintenance............................................................................................. 8-1

8-3. Repair......................................................................................................................... 8-4

8-4. Zero Jig...................................................................................................................... 8-8

8-5. Fuse Replacement...................................................................................................... 8-9

IX. REPLACEMENT PARTS................................................................................................... 9-1

X. RETURNING EQUIPMENT TO THE FACTORY........................................................ 10-1

INDEX ................................................................................................................................................ I-1

APPENDIX A. OPACITY CROSS-REFERENCE TABLE ............................................................ A-1

APPENDIX B. OPACITY MONITORING SYSTEM OPM 2000R SERVICE SCHEDULE......... B-1

APPENDIX C. ROSEMOUNT OPACITY VALUES WORKSHEET............................................. C-1

IB-106-200R

xviii

LIST OF ILLUSTRATIONS

Figure Page

1-1 Standard Model OPM 2000R Transmissometer Opacity/Dust Density Transmitter....... 1-0

1-2 Component Relationships............................................................................................... 1-2

1-3 Calibration Dimensions................................................................................................... 1-3

1-4 Relationship of Opacity, Transmittance, and Optical Density........................................ 1-3

1-5 Example Relationship of Extinction and Dust Concentration......................................... 1-4

2-1 Transceiver Module - Exploded View............................................................................ 2-0

2-2 Transceiver Optical Assembly - Exploded View ............................................................ 2-2

2-3 Stack Light Path............................................................................................................ .. 2-3

2-4 Ambient Light Path......................................................................................................... 2-4

2-5 Dark Mode...................................................................................................................... 2-4

2-6 Lamp Light Path ............................................................................................................. 2-5

2-7 Zero Jig Mounting Location ........................................................................................... 2-6

2-8 Effective Spectral Response Curve................................................................................. 2-6

2-9 Optical Mounting Channel (with Boards)....................................................................... 2-7

2-10 Detector Circuit............................................................................................................... 2-7

2-11 Stack LON Board............................................................................................................ 2-8

2-12 Retroreflector and Air Lens Assembly............................................................................ 2-9

2-13 Air Lens Assembly and Purge Air Failure Flow Switch ................................................. 2-9

2-14 Air Lens Assembly - Exploded View.............................................................................. 2-10

3-1 General Purpose Intelligent Electronics - Exploded View.............................................. 3-1

3-2 IG-1 Software Board....................................................................................................... 3-2

3-3 HART Daughter Board................................................................................................... 3-3

3-4 HART Daughter Board Relay Contact Configurations................................................... 3-5

3-5 Type 4X Intelligent Electronics - Exploded View.......................................................... 3-6

3-6 Termination Board.......................................................................................................... 3-7

3-7 Power Supply.................................................................................................................. 3-7

4-1 Transmitter Location Considerations.............................................................................. 4-0

4-2 Transmitter Location....................................................................................................... 4-1

4-3 Stack Flange Installation................................................................................................. 4-3

4-4 Lifting and Handling....................................................................................................... 4-4

4-5 Stack Installation Dimensions......................................................................................... 4-5

4-6 Intelligent Electronics Mounting Dimensions................................................................. 4-6

4-7 Insulation and Cooling Fin Installation........................................................................... 4-7

4-8 Optional Purge Air Heater.............................................................................................. 4-8

4-9 Customer Connections for OPM 2000R

with General Purpose Intelligent Electronics (Sheet 1 of 2)........................................... 4-10

4-9 Customer Connections for OPM 2000R

with General Purpose Intelligent Electronics (Sheet 2 of 2)........................................... 4-11

4-10 Customer Connections for OPM 2000R

with Optional Type 4X Intelligent Electronics (Sheet 1 of 2)......................................... 4-12

4-10 Customer Connections for OPM 2000R

with Optional Type 4X Intelligent Electronics (Sheet 2 of 2)......................................... 4-13

4-11 General Purpose Intelligent Electronics Relay and Analog Output Connections............ 4-14

5-1 Optical Alignment........................................................................................................... 5-2

5-2 View of Crosshairs and Tolerance Areas in Optical Alignment Sight............................ 5-2

5-3 Objective Lens Adjustment............................................................................................. 5-4

IB-106-200R

xix

LIST OF ILLUSTRATIONS (Continued)

Figure Page

6-1 HART Terminal Connections ......................................................................................... 6-2

6-2 Signa l Line Connections, ≥250 Ohms Lead Resistance.................................................. 6-3

6-3 Signal Line Connections, <250 Ohms Lead Resistance.................................................. 6-4

6-4 HART Communicator Operator Interface....................................................................... 6-5

6-5 Online Menu.................................................................................................................... 6-7

6-6 LCW Locations............................................................................................................... 6-9

6-7 Zero Jig and EPA Filter Placement................................................................................. 6-15

6-8

6-9 Sectored LCW2............................................................................................................... 6-21

6-10 HART Menu Tree for the OPM 2000R (Sheet 1 of 3).................................................... 6-26

6-10 HART Menu Tree for the OPM 2000R (Sheet 2 of 3).................................................... 6-27

6-10 HART Menu Tree for the OPM 2000R (Sheet 3 of 3).................................................... 6-28

7-1 PS1 and PS2 Test Points................................................................................................. 7-6

8-1 External Filters - Exploded View.................................................................................... 8-2

8-2 Internal Filter - Exploded View....................................................................................... 8-3

8-3 Lamp Replacement.......................................................................................................... 8-5

8-4 Detector/Amplifier Board ............................................................................................... 8-5

8-5 Beam Splitter Adjustment and LCW Replacement......................................................... 8-6

8-6 V

8-7 Zero Jig Adjustment and Locking Screws....................................................................... 8-9

lx

and lt Stack Dimensions.............................................................................................. 6-19

Adjustment........................................................................................................... 8-6

LAMP

IB-106-200R

xx

LIST OF TABLES

Table Page

6-1 Function Keys................................................................................................................. 6-6

6-2 Action Keys .................................................................................................................... 6-7

6-3 System Status Modes...................................................................................................... 6-7

6-4 FLD DEVICE VOLTS Sub-menu.................................................................................. 6-8

6-5 LCW States..................................................................................................................... 6-8

6-6 OUTPUT VARIABLES Sub-menu................................................................................ 6-9

6-7 REF. VOLTAGES Sub-menu......................................................................................... 6-12

6-8 FLTR CHK Sub-menu.................................................................................................... 6-14

6-9 SETUP CLOCK Sub-menu............................................................................................. 6-17

6-10 PV, SV, and TV RANGE VALUES Sub-menu.............................................................. 6-18

6-11 DEVICE INFO Sub-menu.............................................................................................. 6-19

6-12 RELAY CONFIG Sub-menu.......................................................................................... 6-20

6-13 ZERO/SPAN CHECK Sub-menu................................................................................... 6-21

6-14 LCW Sector Status.......................................................................................................... 6-22

6-15 AVERAGES Sub-menu.................................................................................................. 6-23

6-16 ALARMS Sub-menu....................................................................................................... 6-24

6-17 DUST SETUP Sub-menu ............................................................................................... 6-25

6-18 REVIEW Menu............................................................................................................... 6-25

7-1 Diagnostic Indicators...................................................................................................... 7-2

7-2 Troubleshooting Chart.................................................................................................... 7-3

9-1 Replacement Parts for General Purpose Intelligent Electronics...................................... 9-4

9-2 Replacement Parts for Type 4X Intelligent Electronics.................................................. 9-4

9-3 Replacement Parts for Transceiver and Retroreflector Modules.................................... 9-4

9-4 Replacement Parts for Transceiver Module.................................................................... 9-5

9-5 Replacement Parts for Retroreflector Module ................................................................ 9-5

9-6 Replacement Parts Kit..................................................................................................... 9-6

9-7 Certified Neutral Density Filters..................................................................................... 9-6

IB-106-200R

xxi

2

HART

MAN4275A00

October1994

Communicator

o

FISHER-ROSEMOUNT

13

1

14

English

TM

3

3a

12

11

4

8

5

10

9

7

6

ITEM DESCRIPTION ITEM DESCRIPTION

1 Transceiver Module 8 751 Field Signal Indicator (optional)
2 Retroreflector Module 9 Communication Cable (optional)
3 General Purpose Intelligent Electronics 10 Purge Air Failure Flow Switch Cable (optional)



3a Type 4X Intelligent Electronics (optio nal) 11 HART

Communications Package (optional)
4 Optical Alignment Sight (optional) 12 Instruction Bulletin
5 6 in. Optical Extension (optional) 13 Power Test Cable
6 LON Communication Test Cable 14 Zero Jig (optional)
7 Power Supply (optional)

Figure 1-1. Standard Model OPM 2000R Transmi s s ometer Opacity/Dust Dens ity T r ans mitter

24670004

IB-106-200R

1-0

SECTION I. SYSTEM OVERVIEW

1-1. COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS).

Rosemount Model OPM 2000R Transmissometer
Opacity/Dust Density Transmitter should contain the
items shown in Figure 1-1.

1-2. SYSTEM OVERVIEW.

a. Scope

b. Reason for Measuring Opacity.

. This instruction bulletin is designed to
supply details needed to install, operate, and
maintain an OPM 2000R.

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.

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 a s a rough indicator
of combustion efficiency. Extreme changes in
opacity may indicate inefficient combustion or

A typical

Opacity refers

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 b ut
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.

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 2000R
contains no moving parts except for blower
motors, which eliminates sources of wear and
possible failure.

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
2000R compensates for the difference between
stack diameter at the exit and stack diameter at
the installation site.

The OPM 2000R is an in

IB-106-200R

1-1

The OPM 2000R consists of a transmitter/
receiver (transceiver) module, a retroreflector
module, and intelligent electronics. 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 upon the particulate content
of the gas stream and the particle type and
size.

TRANSCEIVER

MODULE

LAMP

OBJECTIVE

LENS

The light then strikes a detector, which converts
the light into a voltage that can be 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

COMMUNICATIONS

CABLE TO AND

FROM TRANSCEIVER

WINDOW

ACCESS

PLATE

INTELLIGENT

ELECTRONICS

HART
COMMUNICATOR

24670005

IB-106-200R

1-2

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
2000R calibration and setup. These dimensions
are defined as follows:

lx

lt

lf

The LX/LT parameter is entered in the BASIC
SETUP sub-menu of the HART Communicator.
See paragraph 6-8.c for more information.

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 smoke opacity is also 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 obs erv er.

TRANSCEIVER

MODULE

Figure 1-3. Calibration Dimensions

= inside stack diameter at stack exit.

= inside stack diameter at the transmitter

location.

= flange to flange distance between the

transceiver and retroreflector unit. It is
also the distance that must be used to
calibrate the unit offline.

lx

STACK

RETROREFLECTOR

MODULE

lt

lf

24670006

2.0

1.9

1.8

1.7

D = -log(Tr/100)

OPTICAL DENSITY

(EXTINCTION)

NOTE: THIS INFORMATION IS PROVIDED

IN TABLE FORM IN APPENDIX A.

1.6

1.5

1.4

1.3

1.2

1.1

1.0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0

0% OPACITY

10 20 30 40 50 60 70 80 90 100

100% TRANSMITTANCE 90 80 70 60 50 40 30 20 10 0

Figure 1-4. Relationship of Opacity,

Transmittance, and Optical Density

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 pe rcent 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 op tical
density of two is equal to 99% opacity, etc.

The OPM 2000R 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.

24670007

IB-106-200R

1-3

d. System Considerations.

All procedures in this
manual must be performed carefully in order to
gain the maximum benefit from the OPM 2000R.
Proper maintenance is important for maintaining
signal accuracy and will greatly increase
instrument life.

e. Dust Concentration Measurements.

The OPM
2000R 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 2000R. 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:

1. ISO 9096 Stationary Source Emissions.
Determination of mass concentration and
mass flow rate of particulate matter in gas­carrying ducts - manual gravimetric method.

linearized and represented by the following
equation:

DC = kE + c

Where:
DC = dust concentration
k = slope of dust concentration by extinction

(determined from stack dust sampling
test data)

c = y intercept of dust concentration (deter-

mined from stack dust sampling test
data)

E = Extinction (measured variable by OPM

2000R)

The values for k and c are then entered in the
DUST SETUP sub-menu of the HART
Communicator to calculate the dust concentration
(DC) from the extinction value. Refer to
paragraph 6-9.e for more information.

90

3

80

70

2. ISO/DIS 10155 Stationary Source Emissions.
Automated monitoring of mass concentration
of particles - performance characteristics, test
methods, and specifi cation s.

1-3. METHOD OF M EASUREMENT

. The following
sequence of steps determines the relationship of dust
concentration to extinction readings:

After the OPM 2000R has been installed and is

a.

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 2000R is recorded.

The recorded data is plotted and presented in

b.

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.

A typical graph and dust concentration

c.

calculation (Figure 1-5) shows a linear
relationship between extinction and dust
concentration. The calibration curve can be

60

50

40

95% CONFIDENCE
INTERVAL

0.03

0.04 0.05

= 1940

0.06

24670008

DUST CONCENTRATION (DC) mg/m

16.5

-2.9

30

20

10

0.02

0.01

-10

k=

DC=kE+C
DC = 1940E - 2.9

WHERE:
DC = DUST CONCENTRATION
k = EXTINCTION COEFFICIENT = 1940
c = -2.9

k=

EXTINCTION (E)

DC-C

E

16.5 - (-2.9)

0.01

Figure 1-5. Example Relationship of Extinction

and Dust Concentration

IB-106-200R

1-4

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. The

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 state

Light Source ..................................................... Gas-filled incandescent bulb; expected life greater than

System Shipping Weight................................... 356 lbs (161.5 kg)

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

electronic light modulation; utilizes liquid crystal windows

30,000 hours

Transceiver and Retroreflector:

Enclosure Type................................................. Weather housings are moisture-proof. The transceiver

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 crosshairs

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

O

2

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)

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

IB-106-200R

1-5

Operational:
The OPM 2000R meets EPA design and performance requirements as specified in 40 CFR, Part 60, Appendix B,
Performance Specification 1. The OPM 2000R 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 operating

areas, up to 70% opacity reading. Above 70% opacity

reading, accuracy of ±2% opacity absolute)

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 region);

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 intelligent

electronics processor, 78 k baud

Selectable Parameters....................................... Measurement units

Signal averaging

Optical Path Length Ration (OPLR)

Analog output signal selection

Alarm settings

Manual calibration

Computer-assisted EPA filter check

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

IB-106-200R

1-6

1-5. SYSTEM STARTUP PROCEDURE.

following steps to start the OPM 2000R. 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.

Turn on power to the transceiver and

a.

retroreflector modules immediately after their
installation to the stack or duct. Refer to Section
IV 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.

Turn on the power source to the intelligent

b.

electronics and connect the HART Commu­nicator per paragraph 6-2. Turn on the HART
Communicator and select CHECK OPTICS from
the DIAG/SERVICE menu. Next, select the
V

menu option to place the OPM 2000R in

STACK

the check optics mode.

Align the transceiver and retroreflector. (Refer to

c.

Section V 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.

Set up the operating parameters in the BASIC

d.

SETUP and DETAILED SETUP menus of the
HART Communicator. Refer to paragraphs 6-8
and 6-9 for the complete setup procedures.

Use the

Enter the PROCESS VARIABLES menu and

e.

select FLD DEVICE VOLTS per paragraph
6-6.a. Four voltages are listed: V
V

LAMP

(lamp), V

(ambient), and V

AMB

STACK

DARK

Selecting STACK TEMPERATURE 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 and lamp
voltages will be within 0.5 volts of each other.
The typical values for both stack and lamp volts
as set by the factory are 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.

View the opacity reading on the HART

f.

Communicator display online menu. Ensure the
primary variable (PV) or the secondary variable
(SV) is set to display opacity. Refer to paragraph
6-6.b. 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.

Perform an offline calibration per paragraph

g.

6-7.b. Reference voltages from the last offline
calibration are stored in the REF. VOLTAGES
sub-menu in the DIAG/SERVICE menu. This
stored data should be recorded and saved for later
reference before proceeding with another offline
calibration.

(stack),

(dark).

IB-106-200R

1-7

57

63

58

59

64

65

66

1

NOTE: NOT ALL PARTS SHOWN

ARE AVAILABLE FOR
PURCHASE SEPARATELY.
FOR A LIST OF AVAILABLE
PARTS, SEE SECTION IX.

54

34

53

55

55

56

35

49

52

36

38

48

60

47

51

37

61

62

46

50

40

41

2

39

45

42

3

43

5

4

44

4

12

11

10

6

7

8

9

32

33

31

26

23

25

24

30

27

8

28

29

Figure 2-1. Transceiver Module - Exploded View

IB-106-200R

2-0

20

21

22

19

18

17

13

14

24670029

15

16

SECTION II. TRANSCEIVER AND RETROREFLECTOR MODULES

2-1. TRANSCEIVER MODULE.

nents of the transceiver module (Figure 2-1) are
optical assembly (1, Figure 2-1 and Figure 2-2), air
lens (58, Figure 2-1), and blower motor (5). The three
components are mounted to mounting plate (34) and
enclosed in weather housing (9). The optical
assembly contains all transceiver optical and
electronic components. Lifting and handling
instructions for the transceiver and the retroreflector
can be found in paragraph 4-5.

a. Optical System.

system is a special, long-life incandescent lamp.
The lamp contains a built-in lens that directs light
forward through a 1/8 in. (3 mm) diameter
crosshaired aperture.

The light source for the optical

The main compo-

Two Liquid Crystal Windows (LCWs) function
as shutters that either block or transmit light. The
LCWs are made of a normally translucent film
that scatters the light striking it. However, when
an electric current is applied to the film, the
LCW becomes transparent and allows light to
pass. The sequence in which the LCWs turn on
or off and the duration of each are software­controlled.

LEGEND FOR FIGURE 2-1

ITEM DESCRIPTION

1 Optical Assembly
2 Power Cable
3 Communications Cable
4 Hose Clamp
5 Blower Motor
6 Hex Nut, 1/4-20
7 Lockwash er, 1/ 4 in.
8 Washer, 1/4 in.

9 Weather Housing
10 Mounting Plate
11 Washer, 1/4 in.
12 Pan Head Screw, 1/4- 20 x 7/ 8 in .
13 Mounting Block
14 Toggle Clamp
15 Pan Head Screw, #8- 32 x 3/ 4 in.
16 Pan Head Screw, #8- 32 x 3/ 8 in.
17 Pan Head Screw, #8- 32 x 7/ 8 in.
18 Filter Retainer
19 Wing Nut, 1/4- 20
20 Filter (Coarse)
21 Filter (Fine)
22 Nut, 1/4-20
23 Filter Retainer

ITEM DESCRIPTION

24 Pan Head Screw, #8- 32 x 3/ 8 in.
25 Top Cover Plate
26 Cable Grip
27 Seal
28 Bolt, 1/4-20 x 1- 1/ 4 in.
29 Rivet
30 Latch
31 Conduit Lock Nut, 1/2 in.
32 Gasket
33 Flange
34 Mounting Plate
35 Bolt, 1/4-20 x 5/8 i n .
36 Bottom Cover Plate
37 Standoff, #6- 32 x 1/ 2 in.
38 External Star Washer, #6
39 Screw, #6-32 x 1/4 i n .
40 Ground Cable
41 Termination Board
42 External Star Washer, #6
43 Screw, #6-32 x 1/4 i n .
44 Adapter
45 Filter Base
46 Filter Element Assembly

ITEM DESCRIPTION

47 Filter Cover
48 Flat Washer, 3/8 in.
49 Wing Nut, 3/8- 16
50 Hose
51 Screw, #10-32 x 3/8 i n .
52 External Star Washer, #10
53 Purge Air Failure

Flow Switch Cable
54 Purge Air Failure Flow Switch
55 Straight Connector
56 Air Tubing
57 Stud
58 Air Lens Assembly

(Includes items 59 through 62)
59 Ball Seat
60 Seal Plate
61 Check Valve
62 Adapter
63 Spherical Washer, 3/8 in .
64 Spherical Hex Nut, 3/8- 16
65 Hex Nut, 5/16-18
66 Lockwash er, 5/ 16

IB-106-200R

2-1

43

42

35

41

60

40

36

61

62

37

63

38

39

64

44

45

65

58

61

56

57

51

66

55

52

50

67

54

46

53

68

47

59

2

1

11

10

9

8

7

6

5

4

3

48

49

23

22

18

13

12

17

7

15

16

19

20

21

14

33

34

32

31

30

25

24

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLE

FOR PURCHASE SEPARATELY. FOR A LIST
OF AVAILABLE PARTS, SEE SECTION IX.

29

28

26

27

28

Figure 2-2. Transceiver Optical Assembly - Exploded View

24670009

IB-106-200R

2-2

LEGEND FOR FIGURE 2-2

ITEM DESCRIPTION

1 Cover Plate
2 Thumbscrew, #6-32 x 3/8 in.
3 Splitter Base
4 Socket Head Screw,

#6-32 x 1 in.
5 Beam Splitter
6 Socket Head Screw,

#4-40 x 1/2 in.
7O-Ring
8Aperture
9LCW 1

10 Aperture
11 Mounting Block
12 Retainer
13 Socket Head Screw,

#6-32 x 3/8 in.

14 Electronics Housing
15 Stop Nut
16 Lamp
17 Lamp Holder
18 Socket Head Screw,

#6-32 x 1/2 in.

19 Socket Head Screw,

#6-32 x 1/2 in.

20 Set Screw, 1/4-20 x 1/4 in.
21 Heater

ITEM DESCRIPTION

22 Op tical Mounting Channel
23 CAL/CHECK Backlit

Pushbutton
24 Pan Head Screw, #8-32 x 1/4 in.
25 Latch Clip
26 Conduit Lock Nut, 1/2 in.
27 Mounting Plate
28 Cable Grip
29 Communication Cable
30 Power Cable
31 Flat Washer, 1/4 in.
32 Lockwasher, 1/4 in.
33 Hex Head Bolt, 1/4-20 x 1 in.
34 Window Flange
35 Gasket
36 Threaded Retaining Ring
37 Front Window
38 O-Ring
39 Socket Head Screw,

#6-32 x 5/8 in.
40 Gasket
41 Access Plate
42 Latch Clip
43 Rivet
44 Latch
45 Pan Head Screw, #8-32 x 1/4 in.

ITEM DESCRIPTION

46 Pan Head Screw, #6-32 x 3/8 in.
47 External Star Washer, #6
48 Standoff, #6-32 x 1/2 in.
49 Ground Cable
50 Stack LON Board
51 Socket Head Screw,

#6-32 x 3/8 in.
52 Internal Star Washer, #6
53 Detector Mount
54 Green Filter
55 Detector
56 Detector/Amplifier Board
57 Internal Star Washer, #6
58 Socket Head Screw,

#6-32 x 3/8 in.
59 Standoff, #6-32 x 1/2 in.
60 Socket Head Screw,

#4-40 x 1/2 in.
61 O-Ring
62 Reflector
63 LCW 2
64 Aperture
65 Mounting Block
66 Iris
67 Objective Lens
68 Lens Retainer

Each measurement cycle consists of four different
light path modes; each mode produces a different
voltage. The four measurement modes are stack,
ambient, dark, and lamp and are explained as
follows:

1. Stack Mode. Refer to Figure 2-3. During the
stack mode, the light beam passes through the
aperture (with crosshairs), LCW 1, and beam
splitter. Then, the beam travels through the
objective lens, LCW 2 (center segment), and

APERTURE

(WITH CROSSHAIRS)

LAMP

LCW 1

BEAM

SPLITTER

DETECTOR

OBJECTIVE

LENS

IRIS

COMBINATION

LCW 2

an air window; across the stack; and into a
retroreflector. The retroreflector, by means of a
corner cube, r eflects the light back thr ough the
stack, air window, LCW 2, iris, and objective
lens. The beam strikes the beam splitter and is
reflected into the detector. The detector (a
photodiode) converts the light to a voltage that
can be processed. The desired spectral
response is achieved by a narrow green band
filter on the detector.

24670010

Figure 2-3. Stack Light Path

IB-106-200R

2-3

LAMP

LCW 1

COMBINATION

LCW 2

OBJECTIVE

LENS

DETECTOR

Figure 2-4. Ambient Light Path

2. Ambient Mode. Refer to Figure 2-4. In the
ambient mode, LCW 1 blocks the lamp’s
light, preventing it from ever reaching the
detector. While the lamp light is blocked,
LCW 2 allows ambient light to reach the
objective lens, beam splitter, and detector.

LCW 1

LAMP

DETECTOR

24670011

3. Dark Mode. Refer to Figure 2-5. In the dark
mode, both LCWs are off. The voltage
measured during the dark mode is used to
compensate for any internal light leakage
within the transceiver.

COMBINATION

LCW 2

OBJECTIVE

LENS

24670012

Figure 2-5. Dark Mode

IB-106-200R

2-4

4. Lamp Mode. Refer to Figure 2-6. The lamp
mode allows the OPM 2000R to compensate
for the effects of an aging bulb. In this
mode, the inner segment of LCW 2 is off,
stopping the beam from reaching the air
window and preventing the entrance of
ambient light. The lamp beam is directed
through the objec tive lens and the o uter r ing

segments of LCW 2 to an internal
retroreflector located behind the outer ring
segments. The beam is then directed back
through the objective lens to the beam
splitter and into the detector. The iris
installed over the objective lens can be
adjusted to keep the lamp voltage within
1/2 V of the stack voltage.

LAMP

LCW 1

COMBINATION

IRIS

DETECTOR

LCW 2

RETROREFLECTOR

Figure 2-6. Lamp Light Path

INTERNAL

24670013

IB-106-200R

2-5

ISOLATION

WINDOW

WINDOW

CLEANING

AREA

ZERO JIG

ZERO JIG

LOCATING PIN

WINDOW

FLANGE

Figure 2-7. Zero Jig Mounting Location

b. Filters and Zero Jig.

An external neutral
density filter check is used to meet EPA
requirements concerning monitor accuracy and
calibration. To check the monitor, remove the
window access plate (Figure 2-7) and position
the zero jig onto the window flange. Then, insert
EPA-certified neutral density filters in the zero
jig, one at a time, and compare the filter values
with the actual monitor readings. This
comparison shows the monitor’s accuracy. Refer
to paragraph 6-7.g for complete instructions.

c. Detector/Amplifier PC Board.

The detector is
a photodiode that converts light energy to a
voltage. A green filter in front of the detector is
used to achieve the desired spectral response.
The filter’s maximum response is at 550 nm
(Figure 2-8). At below 400 nm and above
700 nm, the filter transmits less than 2% of the
light.

LATCH

100

90

80

70

60

50

40

RELATIVE RESPONSE, %

30

20

10

0

300 400 500 600 700 800

WINDOW

ACCESS

PLATE

PHOTOPIC REGION

WAVELENGTH, NM

24670014

24670015

IB-106-200R

2-6

Figure 2-8. Effective Spectral Response Curve

Detector CR1 (Figure 2-9) is mounted to the
detector/amplifier PC board, which amplifies the
signal. The board contains a 2-po sition j umper to
adjust the range of gain. If the jumper is in the
low position (JM1), the gain adjustment is from 1
to 10. In the high position (JM2), the gain is from
10 to 100. Potentiometer R1 allows adjustment
within the range determined by the jumpers
(Figure 2-10).

DETECTOR/

AMPLIFIER

BOARD

R1

d. Stack LON Board.

Refer to Figures 2-9 and
2-11. The stack LON board is mounted to the
optical mounting channel. The electronics on the
stack LON board include the communications
electronics, temperature sensor, heater controller,
purge air failure flow switch input modules, and
DC power supplies. Power supply 1 (PS1)
supplies power to the lamp and electronics.
Power supply 2 (PS2) supplies power to LCW 1,
LCW 2, and a status LED.

+15 VDC

DETECTOR

(CR1)

-15 VDC

AMPLIFIER

CIRCUIT

POTENTIOMETER

(R1)

JM1 LOW GAIN

STACK LON

BOARD

DETECTOR (CR1)

(MOUNTED ON

REVERSE SIDE)

JM2 HIGH GAIN

29170006

Figure 2-9. Optical Mounting Channel (with Boards)

+15 VDC

JM1

(LOW)

(X10)

-15 VDC

AMPLIFIER

CIRCUIT

JM2
(HIGH)
(X100)

-0.5 TO +4.75 VDC
(SEE NOTE)

24670017

NOTE: -0.5 VDC AND +4.75 VDC ARE DETECTOR AMPLIFIER SATURATION VALUES. TYPICALLY, LAMP

AND STACK MODE VOLTAGE READINGS ARE +3.0 VDC TO +4.0 VDC. POTENTIOMETER R1 CAN
BE ADJUSTED TO PREVENT AMPLIFIER SATURATION. POTENTIOMETER R1 DOES NOT AFFECT
CALIBRATION.

Figure 2-10. Detector Circuit

IB-106-200R

2-7

e. Termination Board.

Termination board (41,
Figure 2-1) is installed on mounting plate (34)
and provides a connection point for cables to and
from the transceiver. The board provides
connections for the transceiver and retroreflector
purge air failure flow switches, stack LON board
power supplies, and AC power input. Refer to
Figure 4-9 or 4-10 for an illustration and wiring
schematic of the termination board.

f. Heater.

Allowing the temperature in the optical
unit to reach or fall below freezing could result in
improper OPM 2000R operation. For this reason,
a heater is installed on the optical mounting
channel. The temperature circuitry on the stack
LON board turns the heater on when the
temperature in the transceiver assembly is below

85.1°F (29.5°C) and off when the temperature in
the transceiver assembly is above 86°F (30°C).

LCW

DRIVER

CHIP

TO LIQUID

CRYSTAL

WINDOWS

TOLCWs

SERVICE

SWITCH

STATUS

LED

TO LON

TO STACK LON

TERMINATION

BOARD

TO CAL/CHECK

PUSHBUTTON

TEMPERATURE SENSOR

(ON BACK OF BOARD)

TEST

POINTS

SRPOL

+

CAL

PRSW1 PRSW2

LIGHT

HEATER CAL SW

U10 MOUNTED

ON SOLDERSIDE

TOCAL SW
& CALLIGHT

++

ISOLATION

TRANSFORMER

AND LIGHT

TEST

POINTS

+

+15V
AGND

-15V
+60V
+5V
GND
+5VP

-5VP

TO DETECTOR/

AMPLIFIER BOARD

EPROM

+

+

xxx VAC

PARTNUMBER

PS2

3D39698G REV

60V

PS2 60 VDC

POWER
SUPPLY

TODET. BRD

3D39700Gxx

TO LAMP

xxx VAC

PARTNUMBER

PS1 5V,+15V, -15V

PS1 +5 VDC

15 VDC

+
POWER
SUPPLY

PURGE AIR

FAILURE FLOW

SWITCH #1

INTERFACE

MODULE

FUSE 1

TOLAMP

TO PS2
XXXA
250VAC

(SLOW BLOW)

TO PS1
XXXA XXXA
250VAC

(SLOW BLOW)

FUSE 2

FUSE 3

INTERFACE

LINE

FILTER

FUSE CHART

100/115 VAC 220/240 VAC

1A97913H12

1

1A97913H17

PURGE AIR

FAILURE FLOW

SWITCH #2

INTERFACE

MODULE

TO HTR

250VAC
(SLOW BLOW)

HEATER

MODULE

GROUND

PR SW1

PR SW2

HTR

TO

HEATER

TO
HEATER

MAINS &
PR SWS.

TRANSCEIVER

POWER

TO

Figure 2-11. Stack LON Board

IB-106-200R

2-8

1A97913H10

2

1A97913H03

3

1A97913H09

1A97913H16

24670018

2-2. RETROREFLECTOR MODULE.

The retro­reflector module is similar to the transceiver module.
However, instead of an optical assembly (1, Figure
2-1), the retroreflector module has a corner cube
reflector mounted to the air lens assem bly (Figu re 2-12).

3

7

6

2

1

5

4

NOTE 1

NOTE 2

8

The retroreflector consists of retroreflector body
(2, Figure 2-12) and end cap and corner cube
assembly (3). The latter consists of corner cube
holder (4), corner cube (5), gasket (6), and end cap
(zero reflector) (7). Light from the transceiver passes
through the stack and into the retroreflector. The
corner cube reflects the beam back along the same
path. Refer to Section V for more information on
checking and aligning the transceiver and
retroreflector modules.

During calibration, it is possible to simulate 100%
opacity by removing the end cap and corner cube
assembly. Upon removal, reverse the end cap and
reinstall with the flat (zero reflector) side facing the
retroreflector body.

NOTE:

NOT ALL PARTS SHOWN
ARE AVAILABLE FOR PURCHASE
SEPARATELY. FOR A LIST
OF AVAILABLE PARTS,
SEE SECTION IX.

9

NOTE 1:

NOTE 2:

DIFFERENT CORNER CUBES AND HOLDERS
ARE USED AS FOLLOWS:

PATHLENGTH
3 to 10 ft (0.915 to 3.05 m)

10 to 20 ft (3.05 to 6.1 m)

20 to 26 ft (6.1 to 7.9 m)

THE FLAT SURFACE SIDE OF THE END CAP IS A
“ZERO-REFLECTOR” AND CAN BE USED TO SIMULATE
100% OPACITY.

CORNER CUBE

0.5 in. (12.7 mm) Diameter
Corner Cube

1 in. (25.4 mm) Diameter

Corner Cube

1.5 in. (38.1 mm) Diameter
Corner Cube

ITEM DESCRIPTION

1 Air Window
2 Retroreflector Body
3 End Cap and Cor ner Cube Assembly
4 Corner Cube Holder
5 Corner Cube (Retroreflector)
6Gasket
7 End Cap (Zero Reflector)
8 Retaining Strap
9 Screws (3)

29170013

2-3. PURGE AIR FAILURE FLOW SWITCH.

OPM 2000R contains two purge air failure flow
switches (Figure 2-13). One switch is mounted on the
transceiver module mounting plate; the other is
mounted on the retroreflector module mounting plate.
Each switch continuously monitors the differential
pressure across its respective air lens assembly. If the
differential pressure falls below a preset value, the

AIR LENS
ASSEMBLY

STRAIGHT

TO LOW

PRESSURE

SIDE

AIR FROM

BLOWER

PURGE AIR

FAILURE FLOW

SWITCH

FITTINGS

SEAL
PLATE

TO HIGH
PRESSURE
SIDE

24670020

The

Figure 2-12. Retroreflector and Air Lens Assembly

Figure 2-13. Air Lens Assembly

and Purge Air Failure Flow Switch

IB-106-200R

2-9

affected switch opens. The purge air failure flow
switch interface module sends an alarm signal
through the stack LON board to the intelligent
electronics. The intelligent electronics distinguishes
which unit has failed (transceiver or retroreflector)
and displays the flow switch status using a HART
Communicator.

2-4. AIR LENS ASSEMBLY.

An air lens assembly
(Figure 2-14) is mounted to the mounting plate inside
the weather housing of both the transceiver and
retroreflector modules. Each air lens, by receiving
purge air from its own blower, is capable of
maintaining a clean space of air between the module’s

NOTE: NOT ALL PARTS SHOWN ARE

AVAILABLE FOR PURCHASE
SEPARATELY. FOR A LIST OF
AVAILABLE PARTS, SEE SECTION IX.

ITEM DESCRIPTION

1 Convex Washers (4)
2 Concave Washers (4)
3 Adjusting Nuts (4)
4Housing
5 Upper Adapter
6 Check Valve
7 Lower Adapter

12

11

8 Seal Plate

9 Seal Springs
10 Ball Plate Screws (2)
11 Ball Plate
12 Screw
13 Stud (4)

optics and the stack gases and particulates. A manually
positioned sliding seal plate is used to protect the
instrument from flue gases and particulates when the
blower is off. Ball-joint construction of the assembly
provides for horizontal and vertical alignment
adjustments. Refer to paragraph 5-1.

Coarse and fine filters (20 and 21, Figure 2-1) are
located at the bottom of the weather housings. The
filters remove airborne particulates as air is drawn
through the filters by the suction of the blower.
Secondary filter element (46) mounts directly to the
blower intake. The filters can be easily removed for
cleaning and reuse. Refer to paragraph 8-2.d.

3

2

1

13

4

5

9

8

10

Figure 2-14. Air Lens Assembly - Exploded View

IB-106-200R

2-10

6

7

24670021

SECTION III. INTELLIGENT ELECTRONICS

3-1. GENERAL.

The intelligent electronics is the control
unit of the OPM 2000R. It continuously receives
digital signals from the transceiver via the
communications link and converts them into read ings
of opacity, transmittance, optical density, extinction,
and dust density. In addition, the intelligent
electronics sends commands to the transceiver to
initiate diagnostic tests and provides an operator
interface via HART communications.

Two types of intelligent electronics are available: the
standard general purpose version for indoor use and
the optional Type 4X weatherproof version for
outdoor use.

ITEM DESCRIPTION ITEM DESCRIPTION

14-Pin Plug 96-Pin Plug
2 3-Pin Plug 10 9-Pin Plug
3 Screw, M3 x 6 11 Grommet
4 Endplate 12 Standoff, #4-40 x 15/16 in.
5 Enclosure 13 External Star Lockwasher, #4-40
6 IG-1 Software Board 14 Screw, #4-40 x 1/4 in.
7 Lock Nut, #4-40 15 HART Daughter Board
8 Endplate

3-2. INTELLIGENT ELECTRONICS (GENERAL

PURPOSE).

The general purpose intelligent
electronics unit (Figure 3-1) consists of two boards:
the IG-1 software bo ard (6) and the HART daughter
board (15).

a. IG-1 Software Board.

The IG-1 software board
(6, Figure 3-1 and Figure 3-2) contains the
software program, three LED indicators, and
connections to the transceiver, power source, and
HART daughter bo ard (15, Figure 3-1).

1

2

10

14

13

12

11

9

3

8

15

3

4

5

7

6

29170015

Figure 3-1. General Purpose Intelligent Electronics - Exploded View

IB-106-200R

3-1

1. IG-1 Software. The software program that
controls the intelligent electronics resides in
PROM U4 (Figure 3-2). To check the
version level of your software, access the
REVIEW menu using the HART
Communicator. Refer to Section VI for more
information. It is only necessary to replace
the PROM for a software upgrade. The
factory will determine if the software change
is mandatory for units already shipped. If
you require a replacement board, the new
board will contain the latest software
revision.

2. LEDs. Three LEDs are mounted to the side
of the software board: FAULT, COMM, and
POWER.

(a) The yellow FAULT LED turns on

when a fault occurs on the IG-1
software board.

(b) The COMM LED indicates when data

is transferring between the transceiver
and the intelligent electronics. A green
light indicates the intelligent elec­tronics is receiving information. A red
light indicates the intelligent elec­tronics is sending information.

(c) The green POWER LED lights when

the power source to the intelligent
electronics is turned on.

3. LON Connection. The wiring that attaches
to the LON connector provides the
communication link between the intelligent
electronics and the transceiver.

4. +24 V Connection. The +24 V connector is
wired directly to the HART daughter board.

5. RS-232 Connector. The 9-pin connector
establishes a communication link between
the HART daughter board and the software
board.

6. F1 Fuse. This Pico II, 1/2 amp, Slo Blo fuse
provides board circuit protection from the
incoming power source.

b. HART Daughter Board.

The HART daughte r
board (15, Figure 3-1 and Figure 3-3) contains
the real-time clock, relay jumper blocks, and
connections to the transceiver, power source,
HART Communicator, analog outputs, relay
contacts, and digital input.

1. Clock. The HART daughter b oard co ntains
a real-time clock that receives power from
an on-board rechargeable lithium battery
during power outages and when the board is
removed from the intelligent electronics.

2. 4-20 mA LOOP TO STACK Connection
(J2). The wiring that attaches to the
4-20 mA LOOP TO STACK connector
establishes a 4-20 mA signal loop between
the intelligent electronics and the trans­ceiver. The HART Communicator only
operates on the 4-20 mA signal loop. By
running the signal loop between the
intelligent electronics and the transceiver,
you can use the HART Communicator to
interface with the OPM 2000R at either the
intelligent electronics or transceiver instal­lation site.

TO LON

FAULT LED

COMM LED

POWER LED

TO 24 VDC
POWER
SOURCE

IN A NEMA 4X INTELLIGENT ELECTRONICS, THE 24 VDC

NOTE:

CONNECTOR CONNECTS TO A UNIVERSAL POWER SUPPLY
THAT CONVERTS THE INCOMING LINE VOLTAGE TO 24 VDC.

1

LON

2

F1
1/2A
SLO BLO

1 (+)

24 VDC

2 (-)

}

3 (EARTH GND)

U4

SOFTWARE
PROGRAM

Figure 3-2. IG-1 Software Board

IB-106-200R

3-2

NOT USED

TO RS-232
ON HART
DAUGHTER
BOARD

29170007

4-20 mA
LOOP TO
STACK

4-20mA
LOOP
TO STACK

+

-

RELAY JUMPER BLOCKS

J2

+

+

J4

RELAY 3

RELAY 6

RELAY 5

RELAY
CONTACTS

J1

TO RELAY
CONTACTS

J5

DIGITAL

TO DIGITAL
INPUT

TO 24 VDC
POWER
SOURCE

+

-

24VDC

+

­+

-

INPUT

J3

U7

3D39650G REV

RELAY 1

+
+

+

+
+
+

+

REAL-TIME
CLOCK AND BATTERY

NOTE: IN A NEMA 4X INTELLIGENT ELECTRONICS UNIT, THE 24 VDC

CONNECTOR CONNECTS TO A UNIVERSAL POWER SUPPLY THAT
CONVERTS THE INCOMING LINE VOLTAGE TO 24 VDC.

Figure 3-3. HART Daughter Board

3. 24 VDC Connection (J3). The 24 VDC
connector is wired directly to the 24 VDC
power source. Rosemount offers an optional
115 VAC or 220 VAC/24 VDC power
supply that will transform the voltage to the
24 VDC needed.

4. Digital Input (J5). The digital input
connector gives you the opportunity to
initiate a zero/span check via a remote input
such as a computer control system. This is in
addition to the scheduled zero/span check
configured with the HART Communicator.
The contact input is interrogated by the
intelligent electronics with 5 VDC.

5. Relay Contact Connection (J1). The relay
contact connector can be wired to external
devices that utilize OPM 2000R status
indications. The six relays are configured
using the HART Communicator. Refer to
paragraph 6-9.a for more information.

6. Analog Output Connection (J6). The analog
output connector can be wired to a recorder,
controller, or computer that utilizes isolated

RELAY 2

J9

P1

RELAY 4

J11

P1

+

+

RS-232

2

+

J8

ANALOG
OUTPUTS

J6

-

+

J7

3

1

HART

-

­+

+

-

­+

+

+

TO ANALOG
OUTPUT
DEVICES

TO HART
COMMUNICATOR

SWITCHES
(MUST BE IN UP

POSITION FOR
TO RS-232
ON IG-1

INTERNALLY POWERED

SIGNAL LOOPS)
SOFTWARE
BOARD

analog readings from the OPM 2000R. The
three analog outputs are determined by the PV,
SV, and TV values configured using the HART
Communicator. Analog output 1 (AO1), which
always has the PV value, also carries the digital
HART communications signal. Refer to
paragraph 6-6.d for more i nf orm ation.

7. HART Connection (J7). The intelligent
electronics provides two banana jack
receptacle cable assemblies to plug the
HART Communicator into the 4-20 mA
signal loop. The cable assemblies are
located on the endplate of the intelligent
electronics, and their terminals plug into
HART connecto r J7 on the HART da ughter
board. Refer to paragraph 6-2 for more
information on attaching the HART
Communicator to the signal loop.

8. Switches 1, 2, and 3. These switches can be
configured in the up position to power the
analog outputf circuit by the OPM 2000R or
in the down position to power the analog
output circuit by the field device receiving
the analog output signal from the OPM
2000R.

29170002

IB-106-200R

3-3

9. Relay Jumper Blocks (J9 and J11). The
relays on the HART daughter boa rd are now
configurable via two jumper blocks: J9 and
J11 (Figure 3-4). This new feature was
added to provide additional flexibility when
configuring the instrument’s alarm outputs.
J9 can be configured so the instrument’s
relay contacts are either normally energized
or normally de-energized during normal
operating conditions. J11 can b e configured
so the contacts are either normally open or
closed during normal operating conditions.
These terms are explained below:

jumper position for relay 6 is the opposite of
the jumper positions fo r relays 1 through 5.

Two example relay configurations are
default and failsafe.

(a) Default Configuration. The default

configuration of the relays minimizes
the amount of nuisance alarms during
power interruptions to the instrument’s
electronics. This configuration also
minimizes power usage and maximizes
relay life during normal operations.

Normally Open Relay —

A relay with open

contacts when it is in an unpowered state.

Normally Closed Relay —

A relay with
closed contacts when it is in an unpowered
state.

Normally Energized Relay —

A relay with
its coil energized during normal operating
conditions.

Normally De-Energized Relay —

A relay
with its coil de-energized during normal
operating conditions.

Normal Operating Conditions —

The
operating condition when no alarms or
special states are active.

The normally energized/normally de­energized states of relay 6 are reversed in
the on-board logic. Consequently, the

In the default configuration, relays 1
through 5 are normally de-energized
and normally open and relay 6 is nor­mally energized and normally closed.
Therefore, all six contacts are open
during normal operating conditions and
close when an alarm condition occurs.
If a power failure occurs, relays 1
through 5 open a nd relay 6 closes.

(b) Failsafe Configuration. The failsafe

configuration of the relays places nor­mally open relay contacts in a closed
state during normal operating condi­tions and in an open state during an
alarm or no power condition.

In the failsafe configuration, all of the
relays are normally energized and
normally open. Therefore, all of the
relay contacts are closed during normal
operating condi tions and op en when an
alarm or no power condition occurs.

IB-106-200R

3-4

4-20mA
LOOP
TO STACK

+

-

J5

+

-

24VDC

+

-

+

-

J2

DIGITAL
INPUT

J3

U7

+

3D39650G REV

HART DAUGHTER BOARD

J4

+

+

+
+
+

Figure 3-4. HART Daughter Board Relay Contact Configurations

DEFAULT CONFIGURATION

J9

RELAY 1

RELAY 2

NORMALLY

DE-ENERGIZED

RELAY 3

RELAY 4

RELAY 3

RELAY 6

RELAY 5

RELAY
CONTACTS

J1

RELAY 5

RELAY 2

J9

P1

RELAY 1

+
+

+

RELAY 4

J11

P1

+

+

J8

+

RS-232

ANALOG
OUTPUTS

J6

-
+

J7

3

2

1

HART

-

­+

+

-

­+

+

+

NORMALLY

ENERGIZED

NORMALLY

ENERGIZED

RELAY 6

FAILSAFE CONFIGURATION

J9

1

7

13

RELAY 1

14

8222

9333

10

4

11555

12

6

15

16

17

18

RELAY 2

RELAY 3

RELAY 4

RELAY 5

RELAY 6

J11

11

77

1313

1414

88

1515

99

1010

44

1111

1212

66

NO

1616

1717

1818

NC

J11

1

7

13

1482

1593

16

17

18

29170001

NO

104

115

12

6

IB-106-200R

3-5

3-3. TYPE 4X INTELLIGENT ELECTRONICS

(OPTION).

In addition to the IG-1 software board
and the HART daughter board of the intelligent
electronics unit, the Type 4X version (Figure 3-5)
also includes a weatherproof enclosure, power supply,
optional heater, and termination board.

b. HART Daughter Board.

The HART daughte r
board (Figure 3-3 and 9, Figure 3-5) contains the
real-time clock, relay jumper blocks, and
connections to the transceiver, power source,
HART Communicator, analog outputs, relay
contacts, and digital input.

a. IG-1 Software Board.

(Figure 3-2 and 19, Figure 3-5) contains the
software program, three LED indicators, and
connections to the transceiver, power source, and
HART daughter board (9).

The Type 4X and the general p urpose intelligent
electronics units use the same software board.
The only difference that exists is in the 24 VDC
connection. The software board in the general
purpose unit is wired directly to a 24 VDC power
source; the software board in the Type 4X unit is
wired to a universal power supply that transforms
the incoming line voltage into the required
24 VDC.

ITEM DESCRIPTION

1Enclosure
2 Cable Grip
3 Conduit Lock Nut, 1/2 in.
4 Standoff, #6-32 x 1 in.
5 Termination Bo ard
6 Screw, #6-32 x 1/4 in.
76-Pin Plug
89-Pin Plug

9 HART Daughter Board
10 Standoff, #4-40 x 1 in.
11 Standoff, #4-40 x 15/16 in.
12 Screw, #4-40 x 1/4 in.
13 Cable
14 Screw, #10-32 x 3/8 in.
15 Top Cover Plate

16

15

14

J1

J2

18

17

J3

The IG-1 software board

23

22

21

20

19

9

12

13

J7

6

The general purpose and Type 4X units use the
same HART daughter boa rd, but two di fferences
exist. The HART daughter board in the general
purpose unit is wired directly to a 24 VDC power
source; the HART daughter bo ar d in the T ype 4 X
unit is wired to a universal power supply that
transforms the incoming line voltage into the
required 24 VDC.

The other difference is the HART Communicator
connection location. On top cover plate (15) of the
Type 4X unit are two banan a jacks , J2 and J3, used
to attach the HART Communicator to the
4-20 mA signal loop. These banana jacks connect
to HART connector J7 on the HART daughter
board via connector J1 on the top cover plate.

1

24

3

2

10

11

7

8

ITEM DESCRIPTION

16 Standoff, #10-32 x 4 in.
17 4-Pin Plug
18 3-Pin Plug
19 IG-1 S oftware Board
20 Screw, #6-32 x 1/4 in.
21 Power Supply

4

5

22 Standoff, #6-32 x 1/2 in.
23 Heater (Optional)
24 Mounting Plat e

29170016

Figure 3-5. Type 4X Intelligent Electronics - Exploded View

IB-106-200R

3-6

c. Type 4X Enclosure.

Enclosure (1, Figure 3-5) is
weatherproof so the intelligent electronics can be
installed outdoors. Top cover plate (15) provides
convenient access to the 4-20 mA signal loop
needed to attach the HART Communicator
operator interface.

d. Termination Board.

Termination board (5,
Figure 3-5 and Figure 3-6) connects to the
incoming line voltage and supplies the operating
voltage to the power supply and heater. The 5 A,
250 V Slo Blo fuse on the termination board
protects the system components from the incoming
voltage.

GND

M1 M2

SK 1

N1
L3

TO TERMINATION

BOARD

TO HART DAUGHTER

BOARD AND IG-1

SOFTWARE BOARD

24 VDC CONNECTORS

SK 2
1
2
3
4
5
6

+24V
+24V
+24V

COMMON
COMMON
COMMON

24670028

4850B34G REV

TO POWER
SUPPLY

LNLN

J2 J3

J1

LN

TO INCOMING
LINE VOLTAGE

TO HEATER

!

FUSE

Figure 3-6. Termination Board

F1
5A,250VAC
SLO BLO

29170017

Figure 3-7. Power Supply

e. Power Supply.

Universal power supply (21,
Figure 3-5 and Figure 3-7) transforms the
incoming line voltage into the 24 VDC used by
the IG-1 software bo ard and the HART daughter
board. The power supply receives power through
its connection to the termination board
(Figure 3-6).

f. Heater (Optional).

Optional 300 watt heater (23,
Figure 3-5), available in 115 VAC or 220 VAC
depending on the customer requirement, keeps the
Type 4X unit components at an ambient operating
temperature. If the ambient temperature falls below
60°F (16°C), the heater turns on. If the temperature
rises above 75°F (24°C), the heater turns off. The
heater receives power through its connection to the
termination board (Figure 3-6).

IB-106-200R

3-7

32 (813) CLEARANCE
NEEDED TO REMO VE

WEATHER HOUSING

(TYP. BOTH SIDES)

CONDUIT TO

INSTR UMENT

ENCLOSURE

NOTES:

1.

SYSTEM TO BE INSTALLED PER LOCAL AND
NATIONAL ELECTRIC CODES.

2.

FOR U.S. APPLICATIONS, REFER TO E.P.A.
INSTAL L ATION REQUIREMENTS , 4 0 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 P ARENTHESES.

5.

CONNECT WIRING/CONDUIT PER NATIONAL
AND LOCAL ELECTRICAL CODE ST ANDARDS.

PURGE AIR FAILURE
FLOW SWITCH CABLE
(10, FIGURE 1-1)
(SEE NOTE 5)

CUSTOMER-SUPPLIED SIGNAL CABLE

[1 MILE (1.5 KM ) MAXIMUM L ENGTH]

TO INT E L L IGENT
ELECTRONICS

29170011

Figure 4-1. Transmitter Location Considerations

IB-106-200R

4-0

SECTION IV. INSTALLATION

Before starting to install this equipment,
read the "Safety instructions for the
wiring and installatio n of this apparat us"
at the front of this Instruction Bulletin.
Failure to follow the safety instructions
could result in serious injury or death.

4-1. GENERAL.

OPM 2000R Opacity/Dust Density Transmitter
depends on proper installation. All procedures in this
section must be followed carefully.

4-2. CHOOSING A LOCATION.

OPM 2000R is important for obtaining maximum
accuracy in the reading of the stack particulates. Keep
in mind both clearance and process/regulatory
considerations.

a. Clearance Considerations.

Proper functioning of the Rosemount

The location of the

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 4-2.

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 4-1).

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:

LESS THAN
4 DUCT
DIAMETERS

24670062

Figure 4-2. Transmi tter L ocation

IB-106-200R

4-1

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.

4-3. CALIBRATION.

The OPM 2000R is factory
calibrated for the flange-to-flange distance (lf)
(Figur e 1-3) of the installation site. If the unit needs to
be recalibrated, refer to paragraph 6-7.b.

If a Dust Concentration (DC) output is required after
installation, it is necessary to perform isokinetic
sampling on the flue gas while simultaneously
measuring the extinction (E) value. Refer to paragraph
1-3 for a description of th i s procedu re.

4-4. MOUNTING FLANGES TO STACK.

Form two mounting holes in the stack at

a.

locations specified in paragraph 4-2. 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.

Install 6 in. pipe and 6 in., 150 lb flanges

b.

following the notes in Figure 4-3. Pipe must be
horizontal and should protrude at least 4 to 6 in.
(102 to 153 mm).

Weld a flange to each pipe. Align flanges so that

c.

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.

IB-106-200R

4-2

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

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 IN. 150 LB R.F. (RAISED FLANGE)

ANSI FLANGE (B16.5)

SUPPLIED BY CUSTOMER

DIMENSIONS ARE IN INCHES WITH

NOTES:

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.

6.72
(171) I.D.

4

4 (102)

MINIMUM

CLEARANCE

TYPICAL

MASONRY STACK

WALL 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 4-7.b.1 REGARDING THERMO
ISOLATORS.

Figure 4-3. Stack Flange Installation

6

6 IN. SCHED. 40

PIPE SUPPLIED

BY CUSTOMER

METAL WALL STACK

OR DUCT INSTALLATION

5

29170008

°

IB-106-200R

4-3

5

2

4

6

HANDLING PROCEDURE

TO MOUNT ON STACK, REMOVE WEATHER HOUSING
(1) AND OPTICAL ASSEMBLY (2). LIFT MOUNTING
PLATE ASSEMBLY (3) BY A SLING (4) THROUGH THE
AIR WINDOW.

THE AIR LENS SEAL PLATE (6) MUST REMAIN
CLOSED UNTIL THE BLOWER MOTORS ARE
POWERED.

1

4-5. LIFTING AND HANDLING.

Use the following
procedure to hoist the modules to the installation site
and mount them to the stack:

Remove the weather housings by releasing the

a.

four toggle clamps (5, Figure 4-4) that hold each
housing to the mounting plate.

Remove transceiver optical assembly or

b.

retroreflector from air lens assembly (Figures 2-1
and 2-12).

Run a lifting sling through the air lens op ening in

c.

the mounting plate (Figure 4-4). Make sure all
hooking devices are secure. Lift the mounting
plate assembly to the installation site.

4-6. MOUNTING INSTRUCTIONS.

a. Transceiver and Retroreflector Modules.

3

Figure 4-4. Lifting and Handling

2. Make sure heat-resistant gasket (32, Figure

3. Install stabilizers to provide firm support for

Shutter must remain closed until the blower
is powered up.

4. Close air lens assembly shutter (seal plate) (6,

24670032

2-1) 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.

each module and secure with customer­supplied bolts, nuts, and washers from the
inside of the mounting plate (Figure 4-5).

Figure 4-4) until the blowers are powered up.

1. Install customer-supplied 0.75-16 bolts in
the stack mounted spool piece and flange
for the mounting plate per Figures 4-3 and
4-5.

IB-106-200R

5. Install the transceiver optical assembly
and retroreflector to the mounting plates
and install the weather housings to the
modules (Figure 4-5).

4-4

CUSTOMER-SUPPLIED

STABILIZERS

(2 REQUIRED)

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

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

Figure 4-5. Stack Installation Dimensions

IB-106-200R

4-5

b. Intelligent Electronics.

The outline drawings in
Figure 4-6 show the mounting centers and
clearances for the two versions of the intelligent
electronics.

1. General Purpose Intelligent Electronics.

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.

0.177
(4)

(a) Install the general purpose intelligent

electronics no further than 1 mile
(1.5 km) from the stack-mounted
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.

0.57 (14)

4.71

(120)

5.13

(130)

(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 ou t doors.

c. Model 751 Indicator (Optional).

If using the
Model 751 indicator, mount in an accessible
location per the instructions in document PDS
4378A00.

TYPE 4X INTELLIGENT ELECTRONICSGENERAL PURPOSE INTELLIGENT ELECTRONICS

11.00
(279)

8.00

(203)

12.94
(329)

12.50
(318)

NOTE:

5.19 (132)

6.00 (152)

7.00 (178)

DIMENSIONS ARE IN INCHES
WITH MILLIMETERS IN PARENTHESES.

Figure 4-6. Intelligent Electronics Mounting Dimensions

2.72
(69)

IB-106-200R

4-6

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

4-7. MONITORING OPACITY IN HIGH TEMPER-

ATURE 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.

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 offers thermo
isolators for the OPM 2000R’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 2000R. 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 4-7) can be installed between the
duct and the opacity transmitter to ward off
radiant heat. This barrier is recommended
for high radiant heat applic ations 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 applicatio n to be
successful. A flow of cool purge air must be
maintained or the opacity transmitter may
suffer heat damage.

12 IN.

(305 MM)

STACK

OPM

2000R

INSULATION

12 IN.

(305 MM)

MINIMUM

STACK

INSULATION

4TO6IN.

(102 TO 152 MM)

SIDE VIEW FRONT VIEW

FLANGE

COOLING FIN

AND HEAT SHIELD

MINIMUM

Figure 4-7. Insulation and Cooling Fin Installation

IB-106-200R

4-7

INSULATION

24670033

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.

BLK

GRN

WHT

HEATER

WIRE

115 VAC

HEATER

HEATER

WIRE

AIR WINDOW

BLK

GRN

WHT

220 VAC

HEATER

120 VOLT BLOWER

MOTOR JUNCTION

BOX

BLU

YEL

WHT

THERMOSTAT

55 F (13 C) CLOSE

°°

70 F (21 C) OPEN

°°

WHT

BLK

GRN

Figure 4-8. Optional Purge Air Heater

4-8. MONITORING OPACITY AT LOW AM BIENT

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.

240 VOLT BLOWER

MOTOR JUNCTION

BOX

BLK

GRN

b. Solution.

WHT

The OPM 2000R 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 4-8.

4-9. SYSTEM WIRING INSTALLATION.

a. Wiring Practices.

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.

BLU

YEL

29170010

IB-106-200R

4-8

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.

NOTE

If wiring an OPM 2000R with a general
purpose intelligent electronics, refer to
Figure 4-9. If wiring an OPM 2000R with a
Type 4X intelligent electronics, refer to
Figure 4-10.

b. Transceiver Module.

Refer to Figure 4-9 or

Figure 4-10 as appropriate.

1. Make sure communications cable (3, Figure
2-1) from the transceiver is plugged into
connector J2 on the stack termination board.

2. Make sure power cable (2, Figure 2-1) from
the transceiver is plugged into c onnector 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 p late
and tighten the seal onto the cable.

4. Make sure cable (53, Figure 2-1) from the
transceiver purge air failure flow switch is
connected to PR SW 1 connector J7 on the
stack termination board.

module as shown in Figure 4-1. Tighten both
seals at each end of the cable. Connect the wires
to the retroreflector purge air failure flow switch.

d. Blower Motor.

Refer to Figure 4-9 or Figure

4-10 as appropriate.

NOTE

The retroreflector blower motor has its own
independent power source but is wired the
same as the transceiver blower motor at the
motor junction box.

1. Run a line voltage power cable, depending
on the system application, through a cable
grip on the retroreflector mounting plate to
the retroreflector blower motor.

2. Connect the wires at the blower motor
junction box.

3. Tighten the cable seal.

e. General Purpose Intelligent Electronics.

to Figure 4-10.

NOTE

Relay jumper blocks J9 and J11 on the
HART daughter board can be co nfigured for
either the default or failsafe configuration.
For more information, refer to Section III,
INTELLIGENT ELECTRONICS.

1. Run the customer-supplied signal cable
through a suitable conduit.

Refer

Check transceiver data plate for the actual
voltage rating. Failure to connect the power
cable to the appropriate power source will
damage equipment.

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.

6. Refer to paragraph 6-2 for the procedure to
connect the HART communicator to the
4-20 mA signal loop at the transceiver
location.

c. Retroreflector Module.

Refer to Figure 4-9 or
Figure 4-10 as appropriate. Run a customer­supplied cable from PR SW 2 connector J8 on
the transceiver stack termination bo ard thro ugh a
cable grip in the transceiver mounting plate to the
purge air failure flow switch in the retroreflector

2. Connect the signal cable to the 4-20 mA TO
STACK and LON connectors on the
intelligent electronics.

Check the intelligent electronics data plate
for the required intelligent electronics
voltage. Connecting the unit to the wrong
supply voltage will damage the equipment.

3. Attach a customer-supplied 24 VDC power
cable to the two +24 V connectors on the
unit. If a 24 VDC power source is not
available, attach the optional universal
power supply to the two +24 VDC
connectors and plug the power supply into
the customer-supplied voltage source.

4. Connect a customer-supplied digital input
cable for remote initialization of zero/span
checks to the DIGITAL INPUT connector
on the intelligent electronics.

IB-106-200R

4-9

RD
BLK
WH
BLK
SHIELD

J9 CONNECTS TO

GROUND ON

MOUNTING PANEL

POWER TO J7

ON STACK

LON BOARD

STACK

TERMINATION

BOARD

GRN/YLW

WH

BLK

GRN/YLW

WH

CUSTOMER-

SUPPLIED

SIGNAL CABLE

COMMUNICATION

LINK TO TRANSCEIVER

COMMUNICATIONS

CABLE

CABLE GRIP

MOUNTING PANEL

AC POWER

CUSTOMER

WIRING

NOTE 1: BOTH PURGE AIR FAILURE FLOW

NOTE 2: THE OPTIONAL 751 INDICATOR

SWITCHES ARE WIRED THE SAME.
HOWEVER, THE RETROREFLECTOR
PURGE AIR FAILURE FLOW SWITCH
MUST BE WIRED IN THE FIELD,
WHEREAS THE TRANSCEIVER
PURGE AIR FAILURE FLOW SWITCH
IS PRE-WIRED AT THE FACTORY.

CAN BE LOCATED ANYWHERE IN
THE 4-20 mA SIGNAL LINE.

RD

CONNECTIONS

FOR HART

COMMUNICATOR

++

%

++

BLK

WH

BLK

BLK

WH

AC POWER

CUSTOMER WIRING

OPTIONAL 751 INDICATOR
(SEE NOTE 2)

SHIELD

BLK

GRN/YLW

TRANSCEIVER

PURGE AIR FAILURE

FLOW SWITCH

(SEE NOTE 1)

TO RETROREFLECTOR PURGE
AIR FAILURE FLOW SWITCH

A

B

TO INTELLIGENT ELECTRONICS

29170003

Figure 4-9. Customer Connections for OPM 2000R with General Purpose Intelligent Electronics (Sheet 1 of 2)

IB-106-200R

4-10

C

(SEE NOTES 3 AND 4)

GRN/YLW

NOTE 3:

NOTE 4:

BLK

BLU

ORN

WHT

WHT

BLK

BRN

YLW

WHT

GRN/YLW

BLK

BLU

ORN

WHT

GRN/YLW

BLK

BLK

WHT

YLW

BRN

SHIELD
BLK
WH
BLK
RD

4-20mA

TO STACK

LON

DIGITAL INPUT

LED

LED

FAULT

COMM

+24V

LED

POWER

WHT

BLK

+24V

24 VDC
CUSTOMERWIRING
OR OPTIONAL 24 VDC
POWER SUPPLY

GENERAL PURPOSE

INTELLIGENT ELECTRONICS

24670040

Figure 4-9. Customer Connections for OPM 2000R with General Purpose Intelligent Electronics (Sheet 2 of 2)

IB-106-200R

4-11

RD
BLK
WH
BLK
SHIELD

J9 CONNECTS TO

GROUND ON

MOUNTING PANEL

POWER TO J7

ON STACK

LON BOARD

STACK
TERMINATION
BOARD

GRN/YLW

WH

BLK

GRN/YLW

WH

CUSTOMER-

SUPPLIED

SIGNAL CABLE

COMMUNICATION

LINK TO TRANSCEIVER

COMMUNICATIONS

CABLE

NOTE 1: BOTH PURGE AIR FAILURE FLOW

SWITCHES ARE WIRED THE SAME.
HOWEVER, THE RETROREFLECTOR
PURGE AIR FAILURE FLOW SWITCH
MUST BE WIRED IN THE FIELD,
WHEREAS THE TRANSCEIVER PURGE
AIR FAILURE FLOW SWITCH IS
PRE-WIRED AT THE FACTORY.

RETROREFLECTOR PURGE
AIR FAILURE FLOW SWITCH

(SEE NOTE 1)

WHT

CONNECTIONS

COMMUNICATOR

MOUNTING

PANEL

AC POWER

CUSTOMER

FOR HART

CABLE

GRIP

WIRING

BLK

++

%

++

WH

GRN/YLW

OPTIONAL
751 INDICATOR
(SEE NOTE 2)

BLK

TRANSCEIVER

PURGE AIR FAILURE

FLOW SWITCH

(SEE NOTE 1)

AC POWER

CUSTOMER WIRING

A

GRN/YLW

BLK

RD

BLK

WH

BLK

NOTE 2: THE OPTIONAL 751 INDICATOR

SHIELD

TO INTELLIGENT ELECTRONICS

CAN BE LOCATED ANYWHERE
IN THE 4-20 mA SIGNAL LINE.

29170004

Figure 4-10. Customer Connections for OPM 2000R with Optional Type 4X Intelligent Electronics (Sheet 1 of 2)

IB-106-200R

4-12

B

(SEE NOTES 3 AND 4)

GREEN/

GRN/YLW GRN/YLW

YELLOW

BLK

BLU

ORN

FACTORY WIRED

TO POWER SUPPLY

NNLL

J2 J3

L

N

J1

AC POWER CUSTOMERWIRING

(115 OR 220 VAC, 50/60 HZ)

A

B

WHT

WHT

!

WHT
BLK

SHIELD

TO POWER

RD
BLK

TRANSCEIVER
BLOWER MOTOR
JUNCTION BOX
G02 - 220/240 VAC

BRN

BLK

FACTORY WIRED

TO HEATER

F1
5A, 250VAC
SLO BLO

DIGITAL

INPUT

FACTORY

WIRED

SUPPLY

TRANSCEIVER
BLOWER MOTOR

GREEN/

YELLOW

WHT

JUNCTION BOX
G01 - 110/115 VA C

BLK

YLW

BLU

ORN

BRN

CONNECTS TO ITS OWN POWER
SOURCE BUT IS WIRED THE

NOTE 3:

BLOWER MOTOR

WIRING IS BASED ON

GE SUPPLIED

VOLTA

BLK

NOTE 4: THE RETROREFLECTOR MOT OR

.

SAME AS THE TRANSCEIVER
BLOWER MOTOR.

TYPE 4X INTELLIGENT ELECTRONICS ENCLOSURE

RELAYS

TERMINATION
BOARD

4-20mA
LOOP
TO STACK

J2

+

-

J5

DIGITAL
INPUT

+

-

U7

24VDC

J3

+

­+

-

3D39650G REV

1

LON

2

HART DAUGHTER BOARD

+

+

J4

+

+
+
+

+

IG-1 SOFTWARE BOARD

+
+

RELAY 1

RELAY 3

RELAY 2

J9

P1

+

+

J8

RS-232

(TOP CONNECTOR)

PIN 1 - K1+
PIN 2 - K1­PIN 3 - K2+
PIN 4 - K2­PIN 5 - K3+
PIN 6 - K3-

RELAY 6

RELAY
CONTACTS

J1

RELAY 5

RELAY 4

J11

P1

3

J7

HART

2

+

1

+

J8

ANALOG
OUTPUTS
J6

-

+

-

+

­+

­+

­+

WHT

YLW

RELA Y
JUMPER BLOCKS

RELA

YS
(BOTTOM
CONNECTOR)

PIN 1 - K4+
PIN 2 - K4­PIN 3 - K5+
PIN 4 - K5­PIN 5 - K6+
PIN 6 - K6-

ANALOG OUTPUTS

PIN 1 - AOUT1+
PIN 2 - AOUT1­PIN 3 - EARTH GND
PIN 4 - AOUT2+
PIN 5 - AOUT2­PIN 6 - EARTH GND
PIN 7 - AOUT3+
PIN 8 - AOUT3­PIN 9 - EARTH GND

FACTORYWIRED

TO POWER SUPPLY

F1
1/2A
SLO BLO

1 (+)

24 VDC

2 (-)

}

3 (EARTH GND)

U4

FACTORY WIRED
TO RS-232
CONNECTOR
J8 ON HART
DA UGHTER
BOARD

29170005

Figure 4-10. Customer Connections for OPM 2000R with Optional Type 4X Intelligent Electronics (Sheet 2 of 2)

IB-106-200R

4-13

HART

3

112

ANALOG OUTPUTS
PIN 1 - AOUT1+

PIN 2 - AOUT1­PIN 3 - EARTH GND
PIN 4 - AOUT2+
PIN 5 - AOUT2­PIN 6 - EARTH GND
PIN 7 - AOUT3+
PIN 8 - AOUT3­PIN 9 - EARTH GND

3

2

112

2

445

5

RELAYSANALOG OUTPUTS

NOT USED

RELAYS (TOP CONN)

3

3

6

6

PIN 1 - K1+
PIN 2 - K1­PIN 3 - K2+
PIN 4 - K2­PIN 5 - K3+
PIN 6 - K3-

RELAYS (BOTTOM CONN)
PIN 1 - K4+

PIN 2 - K4­PIN 3 - K5+
PIN 4 - K5­PIN 5 - K6+
PIN 6 - K6-

24670041

Check the intelligent electronics data plate
for the required intelligent electronics
voltage. Connecting the unit to the wrong
supply voltage will damage the equipment.

5. Run a customer-supplied 115 VAC or
220 VAC power cable, depending on the
power source, through the cable grip
specified in Figure 4-6. Connect the power
cable to connector J1 on the Type 4X
intelligent electronics termination board as
shown in Figure 4-10. Once the cable is
connected, tighten the cable seal.

6. Make sure connector J2 on the Type 4X
intelligent electronics termination board
connects to power supply connector SK1.

Figure 4-11. General Purpose Intelligent Electronics

Relay and Analog Output Connections

5. Connect a customer-supplied relay output
cable to the RELAYS connector on the
intelligent electronics. Refer to Figure 4-11
to match the terminals to the relay functions.

6. Connect a customer-supplied analog output
cable to the ANALOG OUTPUTS con­nector as shown in Figure 4-11. If any ana­log output is unused, connect a 250 ohm
resistor between the (+) and (-) terminals.

f. Type 4X Intelligent Electronics (Optional).

NOTE

Relay jumper blocks J9 and J11 on the
HART daughter board (Figure 4- 10) ca n be
configured for either the default or failsafe
configuration. For more information, refer
to Section III, INTELLIGENT ELEC­TRONICS.

1. Run the customer-supplied signal cable
through a suitable cond uit.

2. Run the signal cable through the cable gr ip
specified in Figure 4-6.

3. Connect the signal cable to the LON connector
on the IG-1 software board and the 4-20 mA
LOOP TO STACK connector on the HART
daughter board as shown in Figure 4-10.

4. Once the cable is connected, tighten the
cable seal.

7. Make sure power supply connector SK2
connects to the 24 V connectors on the IG-1
software board and HART daughter boa rd.

8. If the optional heater is installed, make sure
connector J3 on the Type 4X intelligent
electronics termination board connects to
the heater.

9. Run a customer-supplied digital input cable
for remote initialization of zero/span checks
through the cable grip sp ecified in Figure 4 -

6. Connect the cable to the DIGITAL
INPUT connector on the HART daughter
board as shown in Figure 4-10. Once the
cable is connected, tighten the cable seal.

10. Run a customer-supplied relay output cable
through the cable grip sp ecified in Figure 4 -

6. Connect the cable to the RELAY
CONTACTS connector on the HART
daughter board. Refer to Figure 4-10 to
match the terminals to the relay functions.
Once the cable is connected, tighten the
cable seal.

11. Run a customer-supplied analog output
cable through the cable grip specified in
Figure 4-6. Connect the cable to the
ANALOG OUTPUTS connector on the
HART daughter board. Once the cable is
connected, tighten the cable seal.

g. Model 751 Indicator (Optional).

Attach the
Model 751 indicator in series with the 4-20 mA
signal loop. See Figure 4-10.

IB-106-200R

4-14

SECTION V. ALIGNMENT

5-1. OPTICAL ALIGNMENT.

Thermal deformation of the stack or duct
can affect the accuracy of the alignment. To
reduce the effects of thermal deformation,
ensure the wall of the stack or duct is
stabilized at the normal operating
temperature prior to performing the final
alignment procedure.

Stack gases can cause serious damage to the
opacity monitor. To prevent damage to the
unit, ensure purge air is on prior to opening
the air lens seal plates. Ensure the seal plates
are closed whenever the purge air blower is
not running.

Turn on power to the transceiver and retro-

a.

reflector.

Run the process long enough to stabilize the

b.

stack walls at normal operating temperature. The
stack walls must be at the same temperature
during final alignment as during the operation
since thermal distortion of the walls can affect
alignment.

Enter the check optics mode as follows:

c.

1. Attach the HART Communicator and turn on
the device. Refer to paragraph 6-2 for HART
Communicator installation information.

2. From the online menu, select DEVICE
SETUP.

3. Next, select DIAG/SERVICE from the
DEVICE SETUP menu.

4. From the DIAG/SERVICE sub-menu, select
CHECK OPTICS.

Failure to remove the OPM 2000R from
automatic control loops prior to performing
the CHECK OPTICS procedure may result
in undesired equipment performance.

5. A “Loop should be removed from automatic
control” warning appears. Remove the OPM
2000R from any automatic control loops and
press OK to continue. Then, an “About to
begin check optics” status message briefly
displays.

6. In the next screen, the system prompts you
to select the LCW state. Select the V
option. The present V

value will

STACK

display. Proceed to the stack. A steady beam
of light should be leaving the transceiver.

At the stack, use a screwdriver to pry open the

d.

latches on the weatherproof housings a nd remove
the weather housings from the transceiver and
retroreflector.

Verify that each purge air blower is running

e.

properly.

STACK

IB-106-200R

5-1

ALIGNMENT

NUT

(4)

SEAL PLATE

END CAP

AND CORNER

CUBE ASSEMBLY

RETROREFLECTOR

BODY

6 IN.

OPTICAL

EXTENSION

TUBE

Figure 5-1. Optical Alignment

VIEW

END CAP

INSTALLED

OPTICAL

ALIGNMENT

SIGHT

A

24670042

Push down the seal plates on both the transceiver

f.

and retroreflector to open the purge air path to
the flue, but do not remove the air lens seal plates
(Figure 5-1).

Align the transceiver as follows:

g.

1. Remove the end cap and corner cube
assembly from the retroreflector body.

2. Attach the optical alignment sight (without
the extension tube) to the retroreflector
body.

NOTE

Three concentric areas are visible through
the alignment sight. Longer pathlengths use
the larger diameter circles.

3. Observe the crosshair image projected by
the transceiver onto the alignment sight.
Note that three concentric areas provide
tolerance definition for three different
pathlength ranges (Figure 5-2).

4. Refer to Figure 5-2. If the crosshair
intersection is within the concentric area for
the given pathlengths, the unit is aligned
within ±2% opacity.

If the crosshair intersection is not in the center o f

h.

the circles, adjust the ball joint in the transceiver
module using the four alignment nuts (Figure 5-1).

3-10 FT

(0.915-3.05 M)

2.00 IN.

(50.8 MM)

AA

DIA REF.

B

10-20 FT

(3.05-6.1 M)

THE FIGURE ILLUSTRATESTOLERANCE AREAS FORTHREE
PATHLENGTH RANGES. THE THREE EXAMPLE READINGS
(FROMTHREE DIFFERENT ALIGNMENTS) ARE AS
FOLLOWS:
A - WITHIN ±2% OPACITY FOR ALL PATHLENGTHS.
B - WITHIN ±2% OPACITY FOR PATHLENGTHS 10 FT

( 3.05 M), BUT OUT OF ALIGNMENT FOR

≥

PATHLENGTHS <10 FT (<3.05 M).

C - WITHIN ±2% OPACITY FOR 20TO 40 FT (6.1 TO 12.2 M)

PATHLENGTHS, BUT OUT OF ALIGNMENT FOR
SHORTER LENGTHS.

C

20-40 FT

(6.1-12.2 M)

≥

24670043

Figure 5-2. View of Crosshairs and Tolerance Areas

in Optical Alignment Sight

IB-106-200R

5-2

When alignment is complete, all four alignment

i.

nuts should be tight.

Align the retroreflector as follows:

j.

1. Remove the alignment sight at the
retroreflector.

2. Attach the 6 in. extension tube and
alignment sight to the retroreflector (Figure
5-1). The extension tube is required to
square the retroreflector to the projected
light beam.

3. Look directly through the alignment sight
and check for a centered beam of light from
the transceiver.

4. Use the alignment nuts on the retrore­flector’s air window to center the beam of
light onto the frosted field of the alignment
sight. Carefully tighten the nuts while main­taining alignment.

5. Recheck the crosshairs by removing the
extension tube. The crosshairs should remain
centered. If not, readjust the transceiver ball
joint.

Remove the alignment sight and extension tube

k.

from the retroreflector.

Install the end cap and corner cube assembly on

l.

the retroreflector.

Install the weatherproof housings over the trans-

m.

ceiver and retroreflector modules .

5-2. OBJECTIVE LENS ADJUSTMENT.

OPM 2000R is configured at the factory for the user’s
stack diameter. If readjustment is ever necessary, the
transceiver assembly and retroreflector body must be
set in a clean environment and at the same distance
apart (flange-to-flange) as when installed on the
stack. The following steps are performed to focus the
objective lens.

Removing covers from the optical assembly
or making optical repairs or adjustments in
an unsuitable environment can affect the
accuracy of the unit. Removal of the
electronics housing and optical cover, as well
as all repairs and adjustments to the optical
assembly, must be performed in a clean,
dust-free environment.

Enter the check optics mode as follows:

a.

1. Attach the HART Communicator to the
4-20 mA signal line and turn on the device.
Refer to paragraph 6-2 for HART Commu­nicator installation information.

2. From the online menu, select DEVICE
SETUP.

3. Next, select DIAG/SERVICE from the
DEVICE SETUP menu.

4. From the DIAG/SERVICE sub-menu, select
CHECK OPTICS.

The

Using the HART Communicator, select the EXIT

n.

option to leave the check optics m ode.

At the “Return control loop to automatic control”

o.

message, return the OPM 2000R to the automatic
control loops previousl y removed and press En t er.

After waiting 30 minutes for the unit to stabilize,

p.

check the calibration. Recalibrate if necessary.
Calibration can be checked by inserting the zero
jig. If opacity differs from 0.0% by more than
±0.5%, recalibrate per paragraph 6-7.b.

Failure to remove the OPM 2000R from
automatic control loops prior to performing
the CHECK OPTICS procedure may result
in undesired equipment performance.

5. A “Loop should be removed from automatic
control” warning appears. Remove the OPM
2000R from any control loops and press OK
to continue. Then, an “About to begin check
optics” status message briefly displays.

IB-106-200R

5-3

6. In the next screen, the system prompts you
to select the LCW state. Scroll to V
and press Enter. The present V

STACK

will display. Proceed to the stack. A steady
beam of light should be leaving the
transceiver.

Remove the end cap from the retroreflector body.

b.

Install the alignment sight in the retroreflector

c.

body (Figure 5-1).

Refer to Figure 2-2:

d.

1. Remove electro nics housing (14).

2. Remove thumbscrew (2) and optical
enclosure cover plate (1).

Refer to Figure 5-3. Loosen the set screws

e.

securing the objective lens.

Slide the objective lens toward the aperture or

f.

away from the aperture.

STACK

value

Reinstall the end cap assembly to the

i.

retroreflector.

Reinstall optical enclosure cover plate (1, Figure

j.

2-2) and secure with screw (2).

Use the HART Communicator to check the

k.

V

STACK

and V

voltages, make adjustments as

LAMP

necessary, and exit the check optics mode as
follows:

1. When prompted for the next step, select the
REFRESH option. Note the current V
value.

2. When prompted again for the next step,
select V

to display the current V

LAMP

value.

3. If V

STACK

and V

are not both 4.0 ±0.1 V,

LAMP

adjust the gain per paragraph 8-3.d.

4. Once the two voltages are 4.0 ±0.1 V, select
the EXIT option.

STACK

LAMP

During the adjustment, look through the

g.

alignment sight at the aperture crosshairs. Stop
the adjustment when the crosshairs are in sharp
focus and tighten the set screws.

Remove the alignment sight from the

h.

retroreflector body (Figure 5-1).

APERTURE

Figure 5-3. Objective Lens Adjustment

SET

SCREWS

OBJECTIVE

5. At the “Return control loop to automatic
control” message, return the OPM 2000R to
the automatic control loops previously
removed and press Enter.

LCW 2

LENS

24670044

IB-106-200R

5-4

SECTION VI. OPERATION

6-1. OVERVIEW.

held communications interface device. It provides the
operator interface to the OPM 2000R. Its 8 line x 21
character liquid crystal display (LCD) and 25 keys are
used to view data and to configure and calibrate the
unit. A pocket-sized manual is also included with the
HART Communicator that details the specific
functions of all the keys.

The HART Communicator accomplishes its task
using a frequency shift keying (FSK) technique. With
the use of FSK, high-frequency digital commu­nication signals are superimposed on the 4-20 mA
transmitter current loop. The communicator does not
disturb the 4-20 mA signals since no net energy is
added to the loop.

To interface with the OPM 2000R, the HART
Communicator requires a termination point along the
4-20 mA current loop and a minimum load resistance
of 250 ohms between the communicator and the
power supply. To simplify the connection procedure,

The HART Communicator is a hand-

the OPM 2000R provides two banana jacks at each of
the transceiver and intelligent electronics sites so the
HART Communicator can be used at either location
as shown in Figure 6-1.

There is an option to interface the HART Commu­nicator with a personal computer by loading the
designated AMS software into the PC and linking the
HART Communicator to the PC using the PC
interface adapter. The adapter connects to the serial
port on the rear panel of the communicator. Refer to
the proper HART Communicator documentation for
more information.

6-2. HART COMMUNICATOR SIGNAL LINE

CONNECTIONS.

connecting the HART Communicator to the signal
line. For applications in which the signal line has a
load resistance of 250 ohms or more, refer to method

1. For applications in which the signal line load
resistance is less than 250 ohms, refer to method 2.

There are two methods of

IB-106-200R

6-1

TRANSCEIVER

STACKTERMINATION BOARD

NOTE: BOARD DETAILSWERE

OMITTED FOR CLARITY.

GENERAL PURPOSE

INTELLIGENT ELECTRONICS

FRONTVIEW

HART

J7

3

3

112

ANALOG OUTPUTS

3

3

112

2

4-20 mA
SIGNAL LINE

LOAD RESISTANCE (R )

2

6

6

445

5

RELAYS

NOT USED

LEAD SET

L

4-20 mA

SIGNAL LINE

4-20mA

TO STACK

J6

LON

BACKVIEW

DIGITALINPUT

+24V

LED

LED

LED

FAULT

POWER

COMMON

J1

LEAD SET

+24V

J6 J10

4-20 mA
SIGNAL LINE

OPTIONALTYPE 4X

INTELLIGENT ELECTRONICS

HARTTERMINATION BOARD

4-20mA
LOOP
TOSTACKTO

STACK

J2

+

-

DIGITAL
INPUT

+

-

24VDC
+

-

+

-

3D39650G REV

TOP COVER PLATE

J1

J2 J3

RELAY

CONTACTS

ANALOG
OUTPUTS

-

+

J7

-

+

HART

-

+

4-20 mA

SIGNAL LINE

LOAD RESISTANCE (R )

J6

L

ANALOG OUTPUT

DEVICE

(ONLY USED IF R

250 OHM LOAD RESISTOR

< 250 OHMS)

L

COMMUNICATOR

Figure 6-1. HART Terminal Connections

HART

LEAD SET

IB-106-200R

6-2

LEAD SET

LOOP

CONNECTORS

SERIALPORT & BATTERY

CHARGER MUST

NOTBE USED IN

HAZARDOUS AREAS

LOOPCONNECTORS

HART COMMUNICATOR

TOP PANEL

USE INTERFACE
00275 0013ONLY

SERIAL PORT

ANALOG OUTPUT

DEVICE

29170018

HART

ANALOG OUTPUTS

112

3

2

>

R 250LΩ

RELAYS

3

3

112

445

NOT USED

2

6

6

5

4-20 mA SIGNAL LINE

3

GENERAL PURPOSE

INTELLIGENT ELECTRONICS

LOOP

CONNECTORS

SERIALPORT & BATTERY

CHARGERMUST

NOTBE USED IN

HAZARDOUSAREAS

LOOPCONNECTORS

USEINTERFACE
002750013 ONLY

SERIAL PORT

HART COMMUNICATOR

TOP PANEL

Figure 6-2. Signal Line Connections,

a. Method 1, for Load Resistance

≥≥≥≥

250 Ohms.

Explosions can result in death or serious
injury. Do not make connections to the
HART Communicator’s serial port, 4­20 mA signal line, or NiCad recharger
jack in an explosive atmosphere.

HART

COMMUNICATOR

ANALOG OUTPUT DEVICE

≥≥≥≥

250 Ohms Lead Resistance

(b) Connect the opposite end of the lead

set to the banana jacks on either the
intelligent electronics or the stack
termination board.

2. If attaching the HART Communicator to an
OPM 2000R using a wiring termination
point in the analog output (AO1) 4-20 mA
signal line, refer to Figure 6-2 and the
following procedure:

LEAD SET

24670049

1. If attaching the HART Communicator to an
OPM 2000R using the banana jacks pro­vided at the stack termination board or the
intelligent electronics, refer to Figure 6-1
and the following procedure.

(a) Connect the supplied lead set to the

loop connectors on the HART Commu­nicator top panel.

IB-106-200R

(a) Connect the supplied lead set to the

loop connectors on the HART Commu­nicator top panel.

(b) Using the banana clips supplied with

the lead set, connect the HART
Communicator in parallel to the load
resistance.

6-3

HART

ANALOG OUTPUTS

112

3

2

RELAYS

3

3

112

445

NOT USED

2

6

6

5

3

GENERAL PURPOSE

INTELLIGENT ELECTRONICS

4-20 mA SIGNAL LINE

250 OHM LOAD
RESISTOR (SEE NOTE)

>

250ΩR

L

ANALOG OUTPUT DEVICE

LOOP

CONNECTORS

SERIAL PORT& BATTERY

CHARGER MUST

NOT BE USED IN

HAZARDOUS AREAS

LOOP CONNECTORS

USE INTERFACE
00275 0013 ONLY

SERIAL PORT

COMMUNICATOR

HART COMMUNICATOR

TOP PANEL

Figure 6-3. Signal Line Connections, <250 Ohms Lead Resistance

b. Method 2, for Load Resistance < 250 Ohms.

Explosions can result in death or serious
injury. Do not make connections to the
HART Communicator’s serial port, 4­20 mA signal line, or NiCad recharger
jack in an explosive atmosphere.

HART

LEAD SET

NOTE: THE SIGNAL LOOP MUST BE

BROKENTO INSERTTHE
OPTIONAL 250 OHM LOAD
RESISTOR.

THE 250 OHM LOAD
RESISTOR IS ONLY USED
IF R < 250 OHMS.

L

(b) Connect the supplied lead set to the

250 ohm load resistor and to the banana
jacks on either the intelligent electronics
or the stack termination board.

2. If attaching the HART Communicator to an
OPM 2000R using a wiring termination
point in the analog output (AO1) 4-20 mA
signal line, refer to Figure 6-3 and the
following procedure:

24670065

1. If attaching the HART Communicator to an
OPM 2000R using the banana jacks pro­vided at the stack termination board or the
intelligent electronics, refer to Figure 6-1
and the following procedure:

(a) Connect a 250 ohm load resistor to the

loop connectors on the HART Commu­nicator top panel.

IB-106-200R

(a) Connect a 250 ohm load resistor to the

loop connectors on the HART Commu­nicator top panel.

(b) Connect the supplied lead set to the

250 ohm load resistor.

(c) At a convenient point, break the analog

output (AO1) 4-20 mA signal line and,
using the banana clips supplied with
the lead set, connect the HART Com­municator to the 4-20 mA signal line.

6-4

6-3. OFFLINE AND ONLINE OPERATIONS.

HART Communicator can be operated both offline
and online.

In the online mode, the communicator is connected

a.

to the 4-20 mA analog output signal line. The
communicator is connected in parallel to the OPM
2000R or in parallel to the 250 oh m load resistor.

Offline operations are those in which the

b.

communicator is not connected to the OPM
2000R. The only offline operation used with the
OPM 2000R is interfacing the HART
Communicator with a PC. (Refer to the
applicable HART documentation regarding
HART/PC applications.)

LCD

DISPLAY

The

6-4. HART OPERATOR INTERFACE DESCRIP-

The HART Communicator (Figure 6-4) has

TION.

an 8-line, 21-character liquid crystal display (LCD)
and 25 keys that provide communication between you
and the OPM 2000R.

a. LCD Display.

When connected to a HART
Communicator, the top line of each online menu
displays the model name of the connected device
and its tag. In addition, the bottom line of each
menu is reserved for the dynamic labels for each
software-defined function key (F1 through F4)
directly below the display.

OPM 2000R @@@@@@
Online

1 Device setup

2 PV 50.00 %
3 SV 12.00 mA
4 TV 0.00 degC
5 Mode Run

FUNCTION KEYS

ACTION KEYS

ALPHANUMERIC KEYS

SHIFT KEYS

F1 F2

I

O

ABC DEF

7

JKL

4

STU

12

#%&

0

F3

GHI

89

PQR

MNO

5

6

YZ/

VWX

3

<>

:+

*

_

.

F4

Figure 6-4. HART Communicator Operator Interface

IB-106-200R

6-5

24670056

b. Function Keys (F1 through F4).

The function
of each key varies depending on the name that
displays above it in the last line of the LCD
display. Table 6-1 provides the location and
purpose of each key.

c. Action Keys.

The action keys are located just
below the function keys on the HART
Communicator. Table 6-2 describes the function
of each key.

If you press only the alphanumeric key within an
edit menu, only the bold numeric character in the
center of the key is selected.

To select the other characters on the key, first
press and release the appropriate shift key and
then press the alphanumeric key. For example, to
select the letter K, first press the second shift key
and then press the K key.

d. Alphanumeric and Shift Keys.

numeric keys (Figure 6-4) can be used to select
menu options or enter data.

F1 F2 F3 F4

HELP

Accesses online help

Activates or deactivates a bit-

enumerated binary variable

RETRY

Tries to re-establish

Deletes current character

communication

EXIT

Leaves the current menu

Sends configuration data to

YES

Answer to yes/no question

Moves up one help screen

ALL

Includes current Hot Key item

Goes to a previous message in

on Hot Key Menu for all

devices

NEXT

Goes to the next variable in

Saves information to memory

offline edit

FILTR

Opens customization menu to

sort configurations

Toggles marked configuration

variables for sending to a

Opens detailed configuration

The alpha-

Table 6-1. Function Keys.

ON/OFF

DEL

SEND

the device

PGUP

PREV

a list of messages

SAVE

module or data pack

MARK

field device

XPAND

information

ABORT

Terminates current task

without saving configuration

Acknowledges information

OK

on the screen

data

ESC

Leaves a value uncha nged

QUIT

Terminates a session because

Accepts user-entered data

Leaves the current menu

ENTER

EXIT

of a communication error

PGDN

Moves down one help screenNOAnswer to yes/no question

NEXT

Goes to the next message in a

list of messages

Includes Hot Key item

ONE

for one device

HOME

Goes to the top menu in the

device description

BACK

Goes back to the menu from

which HOME was pressed

EDIT

Edits a variable value

CMPRS

Closes detailed configuration

information

IB-106-200R

ADD

Adds current item to

Hot Key Menu

6-6

Table 6-2. Action Keys.

KEY FUNCTION

I/O

××××

〉〉〉

〉〉〉

〉〉〉〉〉〉

ÕÕÕÕ

ØØØØ

ÖÖÖÖ

6-5. USING THE HART INTERFACE.

Turns the HART Communicator ON and OFF.
The up arrow key moves the cursor up through

a menu or list of options. An up arrow symbol
next to a menu option on the display indicates
that you can scroll upward for more options.

The hot key provides fast access to your most
frequently used tasks. Refer to the HART
Communicator manual for more information.

The left arrow key moves the cursor to the left
in an editable field or returns to a previous
menu. A left arrow symbol in the top right­hand corner of the display indicates that you
can return to a previous menu.

The down arrow key moves the cursor down
through a menu or list of optio ns. A down
arrow symbol next to a menu option on the
display indicates that you can scroll downward
for more options.

The right arrow key moves the curso r to the
right in an editable field or selects a menu
option. A right arrow symbol next to a
highlighted menu option indicates the option
contains more selections.

Once the HART
Commun i cator i s con n ected t o th e OPM 2000R system,
turn on the HART Communicator using the I/O key.
The first screen that displays is the online menu (Figure
6-5) which has the following menu optio ns: DEVICE
SETUP, PV, SV, TV, and MODE.

NOTE

As you set up your OPM 2000R system,
record all of your settings for reference on
the worksheet provided in Appendix C.

a. DEVICE SETUP.

the menu tree shown in Figure 6-10 at the end of
this section. It contains all of the displays and
procedures used to monitor and control the
OPM 2000R system. Refer to paragraphs 6-6
through 6-10 for more information.

To select a menu option within the DEVICE
SETUP menu structure, either press the right
arrow action key or use the alphanumeric keypad
and press the number that corresponds with the
menu option.

This menu item expands into

b. PV, SV, and TV.

HART terms for primary value, secondary value,
and tertiary value. These menu items are display­only variables that display critical, up-to-date
device information such as opacity, stack
temperature, transmittance, etc. The information
monitored by these three variables are also
connected to the three analog outputs.

c. MODE.

status. The system can be in one of ten modes as
described in Table 6-3. These mode indications
aid in troubleshooting the system. Refer to
Section VII for more information.

The mode continuously disp lays system

PV, SV, and TV are standard

OPM 2000R @@@@@@
Online

1 Device setup

2 PV 50.00 %
3 SV 12.00 mA
4 TV 0.00 degC
5 Mode Run

Figure 6-5. Online Menu

Table 6-3. System Status Modes.

MODE DESCRIPTION
RUN
CAL
OPTICS CHK
FLTR CHK
ZSP CHK
CALF
COMF

SYSFLT

CALF&SYSFLT

FIXED MA

Normal operating mode.
An offline calibration is in progress.
An optics check is in progress.
A filter check is in progress.
A zero/span check is in progress.
The last calibration failed.
A communication failure exists

between the transceiver and the
intelligent electronics.

A system fault condition exists, such
as a lamp failure, high lamp voltage
reading, or blower failure.

The last calibration failed and a
system fault exists.

A trim DAC procedure or loop test is
in progress.

24670057

IB-106-200R

6-7

Table 6-4. FLD DEVICE VOLTS Sub-menu.

V

STACK

MENU

ITEM

TYPICAL

VALUE DESCRIPTION

3.239 V Voltage produced when a generated light beam is sent across the stack

(read-only)
V

LAMP

3.848 V Voltage produced when a generated light beam is reflected within the

(read-only)

V

AMB

0.205 V Voltage produced from the ambient light coming from the stack.

(read-only)
V

DARK

0.343 V Voltage produced when the voltage detector is blocked from the light

(read-only)

Stack Temperature

Vad590

N/A Menu item that further sub-divides into Vad590 and Temp.

3.000 V Voltage produced from the temperature of the optical assembly in the

(read-only)
Temp

27 °C Stack temperature (in °C). The stack temperature is calculated using

(read-only)

6-6. PROCESS VARIABLES Menu.

displays the variables critical to the OPM 2000R
process, such as the voltages produced by the
different light paths in the transceiver and
retroreflector. Also, it gives you the opportunity to
specify three variables (PV, SV, and TV) to monitor
on the online menu.

To access the PROCESS VARIABLES menu, select
the DEVICE SETUP menu item from the online
menu and select PROCESS VARIABLES. Four menu
options are available: FLD DEVICE VOLTS,
OUTPUT VARIABLES, VARIABLE MAPPING,
and VARIABLE RE-MAP.

and reflected back to the transceiver by the retroreflector.

transceiver; used to compensate for the effects of an aging bulb, other
aging components, and power fluctuations.

beam and ambient light; used to compensate for any internal light
leakage within the transceiver.

transceiver; used to calculate the stack temperature.

the following equation:
(Vad590 × 100) - 273 = Stack Temperature

This menu

The light paths are controlled by the Liquid
Crystal Windows (LCWs) shown in Figure 6-6.
The LCWs are transparent when ON and
translucent when OFF. In the translucent state,
light is scattered and effectively blocked. Table
6-5 shows the LCW state for each measured
voltage. LCW 2 has five sectors that can be
individually controlled during the zero and span
checks. See paragraph 6-9.b. During normal
operation, all of the sectors are turned ON and
OFF at the proper time.

Table 6-5. LCW States.

a. FLD DEVICE VOLTS.

This sub-menu displays
the current values of four voltages produced by
the different light paths taken in each
measurement cycle. It also displays the stack
temperature and the voltage needed to calculate
the stack temperature. To access the FLD
DEVICE VOLTS sub-menu, select FLD
DEVICE VOLTS from the PROCESS
VARIABLES menu. The available menu items
are explained in Table 6-4.

V
V
V
V

IB-106-200R

6-8

VOLTAGE LCW 1

STACK

LAMP

AMB

DARK

ON ON OFF

ON OFF ON
OFF ON OFF
OFF OFF OFF

LCW 2

(Sector 5)

LCW 2

(Sectors 1 - 4)

LCW 1

BEAM

SPLITTER

LCW 2

LAMP

DETECTOR

Figure 6-6. LCW Locations

b. OUTPUT VARIABLES.

This sub-menu is used
to identify the three variables (PV, SV, and T V)
that define the analog outputs (AO1, AO2, and
AO3). To access this display, select OUTPUT
VARIABLES from the PROCESS VARIABLES
menu. Selecting a variable on this sub-menu
accesses a display listing the four parameters that
define each variable as explained in Table 6-6.

Table 6-6. OUTPUT VARIABLES Sub-menu.

MENU ITEM DESCRIPTION
PV Output Vars
PV is (read-only)

Displays the four parameters that define PV (analog output 1). N/A
Identifies the type of output variable. PV can represent opacity, transmittance,

optical density, extinction, or dust concentration.

PV Value (read-only)
% Range (read-only)

Displays the PV value in the appropriate units for the variable selected. N/A
Displays the upper range value that corresponds to the full-scale analog output

as a percentage of range. This variable is used to scale the analog output. For
example, if % RANGE is set to 25%, any variable value greater than or equal
to 25% of full range will force the analog output to be 20 mA. Refer to
paragraph 6-8.b for more information.

PV AO (read-only)
SV Output Vars

(read-only)

TV Output Vars
(read-only)

Displays the analog output value in milliamps. N/A
Displays the four parameters that define SV (analog output 2). SV can

represent opacity, transmittance, optical density, extinction, dust concentration,
temperature,

lx/lt,

or one of the 12 averages detailed in paragraph 6-9.c.

Displays the four parameters that define TV (analog output 3). TV can
represent opacity, transmittance, optical density, extinction, dust concentration,
temperature,

lx/lt,

or one of the 12 averages detailed in paragraph 6-9.c.

OBJECTIVE

LENS

c. VARIABLE MAPPING.

24670060

This display-only
menu item identifies the three variables selected
to represent PV, SV, and TV. To access this
display, select VARIABLE MAPPING from the
PROCESS VARIABLES menu. To exit the
display, press Exit.

DEFAULT

SETTING

Opacity

N/A

Transmittance

Temperature

IB-106-200R

6-9

d. VARIABLE RE-MAP.

This procedure allows
you to select the three variables that represent
PV, SV, and TV.

Use the following procedure to change the PV,
SV, and TV output variables.

1. Select VARIABLE RE-MAP from the
PROCESS VARIABLES menu.

Failure to remove the OPM 2000R from
automatic control loops prior to performing
the VARIABLE RE-MAP procedure may
result in undesired equipment performance.

2. Next, a “Pressing OK will change device
output. Put loop in manual” message
appears. Remove the OPM 2000R from any
automatic control loops to avoid undesirable
equipment performance and press OK.

NOTE

The MORE option in the scrollable list
indicates that additional selections are
available on the next screen. However, if
you select the MORE option, you cannot
return to the selections on the previous
screen.

3. The next screen prompts you to select a PV
variable. Select one of the variables from the
scrollable list and press Enter.

6-7. DIAG/SERVICE Menu.

This menu is used to
perform diagnostics to troubleshoot and service the
OPM 2000R. To access the DIAG/SERVICE menu,
select the DEVICE SETUP menu item from the
online menu and select DIAG/SERVICE. Seven sub­menus are available: STATUS, OFFLINE CAL, REF.
VOLTAGES, TRIM DAC, LOOP TEST, CHECK
OPTICS, and FLTR CHK.

a. STATUS.

The menu items in the STATUS sub­menu indicate current instrument status, alarm
status, and possible equipment or communication
failures. Whenever the status mode on the online
menu indicates a CALF, COMF, SYSFLT, or
CALF&SYSFLT mode, access the STATUS sub­menu to display the current instrument status and
alarm statuses that may indicate a possible
equipment or communication failure. All of the
menu items displayed will be either ON or OFF.

To access the STATUS sub-menu, select
STATUS from the DIAG/SERVICE menu.

Refer to Section VII for more information on
how the STATUS menu items are used to
troubleshoot the OPM 2000R.

b. OFFLINE CAL.

The OFFLINE CAL menu item
provides a procedure to perform an offline
calibration. The OPM 2000R is calibrated at the
factory per customer data specifications. Only
recalibrate the unit in a clean laboratory area, or
on a clear stack while using the zero jig option.
The resulting voltages are stored in the non­volatile memory of the software chip on the stack
LON board in the transceiver.

4. The following screen prompts you to select
an SV variable. Select one of the variables
from the scrollable list and press Enter.

5. The next screen prompts you to select a TV
variable. Select one of the variables from the
scrollable list and press Enter.

6. Next, a “Return control loop to automatic
control” note appears. Return the OPM
2000R to the automatic control loops
previously removed and press Enter.

7. Access the VARIABLE MAPPING display
to verify if the variables reflect the latest
changes.

IB-106-200R

To calibrate the unit, use the following
procedure.

1. If calibrating while the unit is installed on
the stack using a zero jig, go to step 2. If
calibrating the unit in a clean laboratory, use
the following procedure:

(a) Remove optical assembly (1, Figure

2-1) from the transceiver module per
paragraph 8-3.a.1.

(b) Remove the retroreflector weather

housing, turn off power to the
retroreflector blower, and remove the
retroreflector body (Figure 5-1). Install
the weather housing on the retro­reflector module.

6-10

(c) Turn off power to the intelligent

electronics (Figure 3-1 or Figure 3-5 as
appropriate). Tag and remove all
cables and wires from the intelligent
electronics and remove the unit from
its mounting location.

(d) Move optical assembly, retroreflector

body, and intelligent electronics to a
clean laboratory.

(e) Set up the transceiver and retro-

reflector in a zero opacity location.
Ensure the test setup has the same
flange-to-flange distance

(lf)

as on the
stack and make sure the transceiver and
retroreflector are properly aligned.
Refer to Section V for alignment
information if necessary.

2. If not attached, connect the HART Commu­nicator at the stack termination board or the
intelligent electronics per paragraph 6-2 and
turn on the comm u n icator.

3. If using a zero jig for this offline calibration,
insert the jig per paragraphs 6-7.g.2(c)
through (e).

4. Select OFFLINE CAL from the DIAG/
SERVICE menu.

5. The first screen prompts you to press the
pushbutton light to begin the calibration.
Press the CAL/CHECK backlit button
(Figure 6-7) on the front mounting plate of
the transceiver, and the system automatically
begins to measure 0% opacity and record
0% opacity reference volts.

(f) Connect the LON test cable to

communications cable (3, Figure 2-1)
and the LON connector on the
intelligent electronics.

(g) Connect the transceiver power test

cable to power cable (2) and a suitable
voltage source.

(h) Connect the HART Communicator to

the intelligent electronics and turn on
the communicator.

(i) To access the FLD DEVICE VOLTS

sub-menu, select DEVICE SETUP
from the online menu and select
PROCESS VARIABLES. Next, select
FLD DEVICE VOLTS. Examine the
V

STACK

and V

variables. Both

LAMP

variables should be between 3.0 and

4.0 V.

(j) If necessary, remove electronics

housing (14, Figure 2-2) to adjust the
gain potentiometer on the detector
amplifier board so both the V
V

values are between 3.0 and

LAMP

STACK

and

4.0 V. For best performance, try to
adjust V

STACK

and V

to 4.0 ±0.1 V.

LAMP

Refer to paragraph 8-3.d for the
procedure to adjust the gain.

(k) Insta ll electronics housing (1 4).

(l) Make sure the laboratory is dimly lit

before performing the offline calibra­tion procedure.

6. The next screen informs you to wait while the
system performs a 0% calibration. Once 0%
calibration is complete, the system instructs
you to turn the corner cube around and press
the pushbutton light to begin 100%
calibration. The back of the corner cube is a
black reflector that simulates 100% opacity. If
the zero jig is in use, insert the black paddle
that shipped with the zero jig instead of using
the back of the corner cube. Press the
CAL/CHECK backlit pushbutton on the front
mounting panel of the transceiver.

7. The next screen informs you to wait while
the system performs a 100% calibration.
When 100% calibration is complete, the
system instructs you to turn the corner cube
back around and press the pushbutton light
to continue. If the zero jig is in use, remove
the black paddle from the zero jig instead of
turning the corner cube around. Press the
CAL/CHECK backlit pushbutton on the
front mounting panel of the transceiver.

8. Next, the screen displays the current PV value
and Optical Correction Factor (OCRF) and
gives you three options: REFRES H, CHANGE
OCRF, and END CALIBRA TION.

The OCRF provides a correction factor for
an offline calibration. Normally, this value
should be left at 0.00. If certified neutral
density filters (NDFs) are available, they can
be inserted into the light path to verify the
calibration. The OCRF can then be adjusted
to force the unit to better match the filter
values. The OCRF is a percent of reading

IB-106-200R

6-11

correction and is limited to ±10%. This
factor normally is not required because the
OPM 2000R is capable of measuring well
within 2% opacity.

The following example demonstrates the use
of the OCRF.

10. Select the REFRESH menu item to update
the PV and OCRF values.

11. Select END CALIBRATION to return to the
DIAG/SERVICE menu.

12. Remove the zero jig if it is in use.

NOTE

In these examples,

lx/lt

equals 1. If

lx/t

does

not equal 1, correct the opacity reading for

lx/lt

. Refer to paragraph 6-7.g.4. Then,

adjust the OCRF if necessary.

The certified values for three different NDFs
are the following:

NDF #1 = 8.1%
NDF #2 = 20.5%
NDF #3 = 37.9%

During an offline calibration of the OPM
2000R, the three NDFs have the following
opacity readings while the OCRF equals 0:

NDF #1 = 8.5%
NDF #2 = 22.5%
NDF #3 = 41.0%

Since the opacity readings of the three NDFs
are not the same as their certified values, the
OCRF should be changed to make the
opacity reading more accurate. When the
OCRF is changed to 2, the three NDFs have
the following opacity readings:

NDF #1 = 8.65%
NDF #2 = 22.9%
NDF #3 = 41.6%

When the OCRF is changed to -10, the three
NDFs have the following opacity readings:

NDF #1 = 7.7%
NDF #2 = 20.5%
NDF #3 = 37.8%

In this example, changing the OCRF value
to -10 is the best setting because it changes
the opacity readings of all three of the NDFs
closest to their certified values—NDFs 2
and 3 in particular.

9. To change the OCRF, select the CHANGE
OCRF menu item, change the OCRF to a
value between -10.0 and +10.0, and press
Enter.

c. REF. VOLTAGES.

menu displays voltages that were measured
during the last offline calibration at 0% opacity
and at 100% opacity. It also displays the date and
time of the last offline calibration. The current
voltages can be compared to the reference values
to determine how much they have changed since
the last calibration. The opacity monitor formulas
compensate for changes in ambient light and the
lamp intensity. Table 6-7 identifies the reference
voltages and provides typical values for each. For
definitions of the voltage values refer to Table
6-4.

Table 6-7. REF. VOLTAGES Sub-menu.

MENU

TYPICA

ITEM

VALUES

CalDate

10/21/97 Date of the last calibration

(read-only)

CalTime

02:00 Time of day of the last

(read-only)

V

STACK

0

3.972 Voltage value at 0% opacity.

(read-only)
V

LAMP

0

3.691

(read-only)
V

0

AMB

0.399

(read-only)
V

DARK

0

0.186

(read-only)
V

STACK

1

1.207 Voltage value at 100% opacity.

(read-only)
V

LAMP

1

3.694

(read-only)
V

1

AMB

0.187

(read-only)
V

DARK

1

0.184

(read-only)
OCRF

0.000 Correction factor for an offline

(read-only)

REF. VOLTAGES sub-

L

DESCRIPTION

(DD/MM/YY). This parameter
automatically updates upon
calibration.

calibration (HH:MM). This
parameter automatically updates
upon calibration.

calibration.

IB-106-200R

6-12

d. TRIM DAC.

The TRIM DAC procedure is used
to calibrate the PV (AO1) 4-20 mA signal loop
by referencing a high and low count. The PV
needs to be trimmed because it uses an integrated
circuit to control AO1 that is different than the
circuits in SV and TV. The digital information
needed to set the analog output correctly varies
between integrated circuits. Therefore, to make
the integrated circuit accurate, the software needs
the digital information collected by trimming the
analog output. This diagnostic procedure helps to
maintain optimum accuracy and efficiency when
communicating with other devices.

6. When the “Returning fld device to original
output” message displays, remove the
reference meter from the analog output
connections and press Enter.

7. Next, a “Loop may be returned to automatic
control” note appears. Return the OPM
2000R to the automatic control loops
previously removed and press Enter. If you
were to repeat the TRIM DAC procedure, the
values that display on the reference meter will
match the output of the digital-to-analog
converter.

In the TRIM DAC procedure, the OPM 2000R is
placed in the fixed mA mode in which the digital­to-analog converter outputs a specified milliamp
signal, such as 4 mA. By attaching a reference
meter to the analog output connections, you can
view what the instrument is actually outputting,
which may not be 4 mA. The TRIM DAC
procedure uses the reference meter value to
calibrate the digital-to-analog converter to ensure it
outputs 4 mA. Use the following procedure to
calibrate the analog outputs:

1. To access the TRIM DAC procedure, select
TRIM DAC from the DIAG/SER VICE m enu .

Failure to remove the OPM 2000R from
automatic control loops prior to performing
the TRIM DAC procedure may result in
undesired equipment performance.

2. Next, a “Loop should be removed from
automatic control” warning appears. Remove
the OPM 2000R from any automatic control
loops to avoid undesirable equipment per­formance and press En ter.

3. The next screen directs you to connect a
reference meter. Connect an ammeter to the
analog output connections (Figure 4-10 or
Figure 4-11 as appropriate) o n the intelligent
electronics and press Enter.

4. Next, the screen prompts you to enter the
meter value. Observe the value displayed on
the reference meter, enter that value, and
press Enter.

5. Next, the screen prompts you to enter the
meter value. Observe the value displayed on
the reference meter, enter that value, and
press Enter.

e. LOOP TEST.

The loop test is a diagnostic
procedure that allows you to apply a specific
current to the 4-20 signal loop to verify that the
analog output is connected correctly. To access
this sub-menu, select LOOP TEST from the
DIAG/SERVICE menu.

1. To verify the current in analog output 1,
select LOOP TEST PV from the LOOP
TEST sub-menu.

Failure to remove the OPM 2000R from
automatic control loops prior to performing
a loop test may result in undesired equipment
performance.

2. Next, a “Loop should be removed from
automatic control” warning appears.
Remove the OPM 2000R from any
automatic control loops to avoid
undesirable equipment performance. At
this time, also install a reference meter to
analog output 1 that will register the signal
current. To continue the procedure, press
Enter.

3. The next screen prompts you either to select
a current or to end the test. Choose 4 mA,
20 mA, or OTHER, which gives you the
opportunity to enter a different value.

4. Once you make your selection, check the
reference meter. If the reference meter
value does not match the selected value,
you must check your connections. If the
values match, analog output 1 is connected
correctly.

IB-106-200R

6-13

5. Select END to leave the LOOP TEST
procedure.

6. Next, a “Loop may be returned to automatic
control” note appears. Return the OPM
2000R to the automatic control loops
previously removed, disconnect the ref­erence meter, and press Enter.

7. To verify the analog output 2 or 3, repeat
steps 1 through 6 for LOOP TEST SV or
LOOP TEST TV, respectively.

f. CHECK OPTICS.

Refer to Section V for the

complete CHECK OPTICS procedure.

g. FLTR CHK.

The menu items in the FLTR CHK
sub-menu are used to verify the calibration
validity of the OPM 2000R using a zero jig and
neutral density filters (NDFs). A set of three
different NDFs are used multiple times to comply
with the EPA Filter Check Method 203 Audit.
Typically, this procedure takes less than one
hour. NDFs placed in the zero jig will display
NDF values corrected for the pathlength
correction ratio (OPLR)—referred to as the
ratio in the OPM 2000R. The values will be in
the units configured for PV. These measurements
are stored by the OPM 2000R and recorded using
a data recorder connected to analog output 1. To
access this sub-menu, select FLTR CHK from the
DIAG/SERVICE menu. Refer to Table 6-8 for
descriptions of the available menu items.

Table 6-8. FLTR CHK Sub-menu.

MENU

ITEM DESCRIPTION

Filter Check
(method)

Provides the procedure to check the
NDFs to comply with the EPA Filter
Check Method 203 Audit.

Fltr Chk
Values
(method)

Provides the procedure to display each
neutral density filter value, in terms of
PV, by selecting the filter number. It also
displays time (HH:MM) the value was
taken.

Erase Fltr
Values
(method)

Provides the procedure to erase test filter
data currently stored by the OPM
2000R. The old filter data is usually
erased before starting a new filter check.

lx/lt

1. Use the following procedure to erase test
filter data currently stored by the
OPM 2000R:

NOTE

If the stored filter values are erased before
starting the FILTER CHECK procedure,
the procedure will begin at filter 1. If the
stored filter values are not erased before
starting the FILTER CHECK procedure,
the procedure will begin where it previously
ended.

(a) Select ERASE FLTR VALUES from

the FLTR CHK sub-menu.

(b) Next, an “About to erase filter values”

message appears. Press Enter to clear
all values of previous filter checks or
press Abort to exit from the screen
without erasing the values.

2. Perform the filter check procedure as
follows:

(a) Select FILTER CHECK from the

FLTR CHK sub-menu.

Failure to remove the OPM 2000R from
automatic control loops prior to performing
the FILTER CHK procedure may result in
undesired equipment performance.

(b) Next, a “Loop should be removed from

automatic control” warning appears.
Remove the OPM 2000R from any
automatic control loops to avoid
undesirable equipment performance
and press Enter.

(c) The next sc reen displays an “About to

begin filter check” message. At this
time, remove the window access plate
from the transceiver optical assembly
(Figure 6-7).

IB-106-200R

6-14

NOTE: FLANGE NOZZLE

PARTIALLY CUT AWAY
TO SHOW PHANTOM
VIEW OF LOCATOR PIN.

WINDOW

ACCESS

PLATE

WINDOW

CLEANING

AREA

MAGNETS

NEUTRAL
DENSITY
FILTER

WINDOW
FLANGE

LOCATOR PIN
(SEE NOTE)

CAL/CHECK
BACKLIT
PUSHBUTTON

ZERO JIG

LOCATOR
PIN SLOT

24670061

Figure 6-7. Zero Jig and EPA Filter Placement

NOTE

A zero jig is specific to the transceiver to
which it has been calibrated. Check that the
serial number of the zero jig is the same as
the serial number of the transceiver.

The zero jig requires periodic calibration
(typically once per year). Refer to para­graph 8-4 for the zero jig calibration
procedure.

(d) Remove the keepers from the zero jig

magnets and place the zero jig through
the window cleaning area. Slide the jig
on the window flange and onto the
locating pin.

(e) Slightly rotate the jig back and forth

until the 2 in. (50.8 mm) diameter
raised section falls into place. The
locator pin and the two permanent
magnets hold the jig in position.

(f) Insert neutral de nsity filter 1.

(g) Press Enter on the HART Com m unicator.

(h) The next screen prompts you to press

the pushbutton light to begin reading
filter 1. Press the CAL/CHECK backlit
button on the front mounting plate of
the transceiver.

(i) The following screen informs you to

please wait (approximately five
seconds) while the system is reading
the filter.

(j) At the prompt to begin reading filter 2,

remove filter 1, and insert filter 2.

(k) Repeat steps (g) through (j) for the

remaining filters.

(l) If you do not wish to check all 30

filters, press Abort to exit the FILTER
CHK procedure.

(m) At this time, remove the neutral density

filter and zero jig from the transceiver
(Figure 6-7).

IB-106-200R

6-15

The zero jig is a sensitive, calibrated
instrument. Store the jig in its protective
case when not in use. Failure to properly
store the jig can lead to damage or an out­of-calibration condition.

To determine the correct expected opacity
value at your site, use the following
procedure:

(a) Convert the NDF-certified opacity

value to the equivalent optical density
(OD) value using the table in
Appendix A.

(n) Install the keepers on the zero jig

magnets and return the jig to its
protective case.

(o) Install the window access plate.

(p) When the “Loop may be returned to

automatic control” note appears, return
the OPM 2000R to the automatic
control loops previously removed and
press Enter.

3. Use the following procedure to view the
filter check values:

(a) Select FLTR CHK VALUES from the

FLTR CHECK sub-menu.

(b) T he next screen prompts you to select

a filter. Enter the number of the filter
(1 through 30) you wish to view and
press Enter.

(c) The following screen displays the filter

number; the filter value, in terms of
PV; and the time the filter was
checked. To view another filter, select
the NEW FILTER option. To exit the
procedure, select EXIT.

4. The OPM 2000R adjusts all readings for the

lx/lt

ratio, including those taken with an NDF.
The NDF-certified opacity values are based
on an

lx/lt

ratio of 1.0. If the

lx/lt

ratio at your
site is not equal to 1.0, an adjustment must be
applied to the given NDF-certified opacity
value that will yield the correct expected
value for your specific site.

(b) Multiply the OD value by the

to get an expected OD value.

(c) Convert the expected OD value back to

an (expected) opacity value using the
table in Appendix A.

The equation for the relationship is as
follows:

expected NDF OD value = certified OD value *

Example 1:

lx/lt

ratio = 0.8
certified NDF opacity value = 36.9%
certified OD value = 0.2000 (from

Appendix A)

expected NDF OD value = 0.2

* 0.8 = 0.16

expected NDF opacity value = 30.8%

(from Appendix A)

Example 2:

lx/lt

ratio = 0.8
certified NDF opacity value = 87.4%
certified OD value = 0.9000 (from

Appendix A)

expected NDF OD value = 0.9

* 0.8 = 0.72

expected NDF opacity value = 80.9%

(from Appendix A)

Example 3:

lx/lt

ratio = 3.0
certified NDF opacity value = 36.9%
certified OD value = 0.2000 (from

Appendix A)

expected NDF OD value = 0.2

* 3.0 = 0.6

expected NDF opacity value = 74.9%

(from Appendix A)

lx/lt

lx/lt

ratio

ratio

IB-106-200R

6-16

6-8. BASIC SETUP MENU.

This menu is used to view
and configure basic system requirements. To access
the BASIC SETUP menu, select the DEVICE SETUP
menu item from the online menu and select BASIC
SETUP. Four sub-menus are available: SETUP
CLOCK, RANGE VALUES, LX/LT, and DEVICE
INFO.

4. The system then returns to the SETUP
CLOCK sub-menu. Verify that the read-only
displays in the sub-menu reflect the latest
changes.

Table 6-9. SETUP CLOCK Sub-menu.

a. SETUP CLOCK.

This sub-menu displays the
real-date and real-time and provides a procedure
to reset both. To access the SETUP CLOCK sub­menu, select SETUP CLOCK from the BASIC
SETUP menu. The menu items available are
explained in Table 6-9.

Use the following procedure to change the date
and time:

1. From the BASIC SETUP sub-menu, Select
CLOCK SETUP.

2. The next three screens will prompt you to
enter the current date in month, day, and
year, respectively. After typing each entry in
the highlighted area, press Enter.

3. The next three screens will prompt you to
enter the current time in hours, minutes, and
seconds, respectively. After typing each
entry in the highlighted area, press Enter.

MENU

ITEM

Date
(read­only)

Time
(read­only)

Clock
Setup
(method)

TYPICAL

VALUE DESCRIPTION

09/30/97 Displays the current date (in

MM/DD/YY). The date is
maintained by the real-time
clock chip on the HART
daughter PC board. A batter y
on the board backs up the real­time clock in the event of a
power failure.

09:30:27 Displays the current time (in

HH:MM:SS). The time is
maintained by the real-time
clock chip on the HART
daughter PC board. A batter y
on the board backs up the real­time clock in the event of a
power failure.

N/A Provides the procedure to reset

the date and time of the internal
clock.

IB-106-200R

6-17

Table 6-10. PV, SV, and TV

RANGE VALUES Sub-menu.

MENU ITEM DESCRIPTION

Select PV Range

Contains the following three
parameters that define the PV
range.

URV
(read-only)

Displays the upper range value for
the selected variable as a percentage
of the analog output. A typical
value for this variable is 100.00%.
The URV can be modified using the
PV RANGE SETUP method.

LRV
(read-only)

Displays the lower range value for
the selected variable as a percentage
of the analog output. A typical
value for this variable is 0.00%.
This parameter cannot be modified.

PV Range Setup
(method)

Select SV Range

Provides the procedure to change
the URV of the selected variable.

Refer to the Select PV Range menu
item.

Select TV Range

Refer to the Select PV Range menu
item.

Failure to remove the OPM 2000R from
automatic control loops prior to performing
the URV procedure may result in undesired
equipment performance.

2. Next, a “Loop should be removed from
automatic control” warning appears.
Remove the OPM 2000R from any
automatic control loops to avoid undesirable
equipment performance and press Enter.

3. The next screen prompts you to enter a new
upper range value for analog output 1 (PV).
Type the value in the highlighted area and
press Enter. A typical value for this variable
is 100.00% of the analog output.

4. A “Saving range values” message displays
while the system updates.

5. Next, a “Loop may be returned to automatic
control” note appears. Return the OPM
2000R to the automatic control loops
previously removed and press Enter. Verify
that the read-only URV menu item reflects
the change.

b. RANGE VALUES.

The RANGE VALUES
sub-menu allows you to set up the ranges for the
user-selected PV, SV, and TV variables (analog
outputs 1, 2, and 3). To access this sub-menu,
select RANGE VALUES from the BASIC
SETUP menu. The menu items are SELECT PV
RANGE, SELECT SV RANGE, and SELECT
TV RANGE. The menu items for this sub-menu
are explained in Table 6-10.

Use the following procedure to change the URV
for the PV range:

1. From the SELECT PV RANGE sub-menu,
select PV RANGE SETUP.

6. Repeat steps 1 thr ough 5 for the SV and TV
URV values.

NOTE

If any of the three HART variables (PS, SV,
or TV) have the same process variable (i.e.,
opacity, transmittance, average 1, etc.),
setting the URV of one analog output will
affect the URV of each analog output whose
corresponding HART variable has been
assigned the same process variable. For
example, if SV and TV are both assigned
the process variable of opacity, then setting
the URV of analog output 2 (SV) to 50%
will automatically set the URV of analog
output 3 (TV) to 50%.

IB-106-200R

6-18

lx/lt

c. 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. See Figure
6-8. If the ratio is greater than 1.0, the exit
opacity will be greater than the opacity at the
instrument location. The OPM 2000R uses this
correction factor to calculate the stack exit
opacity. It is not practical to have an

lx/lt

much greater than 2.0 because the error of the
instrument increases as

lx/lt

becomes greater.

The LX/LT sub-menu allows you to view and
configure the
a read-only display of the current

lx/lt

ratio. The LX/LT menu item is

lx/lt

default setting is 1.00. This value can be changed
using the LX/LT SETUP menu item.

factor

value. Its

Table 6-11. DEVICE INFO Sub-menu.

MENU ITEM DESCRIPTION

Dev id
(read-only)

Identifies the device used with the
HART Communicator. The device
ID also appears at the top of each
screen in the HART Communicator.

Descriptor
(read, write)

Tag
(read, write)

Provides a 16-character entry to
convey user information.

Provides an 8-character entry to
convey user information. Appears
on the top line of every HART
display next to the device ID.

Message
(read, write)

Provides a 32-character entry to
convey user information.

Use the following procedure to change the
variable:

1. From the LX/LT sub-menu, select LX/LT

2. The next screen prompts you for the

TRANSCEIVER

MODULE

lx/lt

SETUP.

lx/lt

variable. Calculate the ratio to three decimal
places by dividing the inside diameter of the
top of the stack (lx) by the inside diameter
of the stack at the instrument (lt). Type the
new value in the highlighted area and press
Enter.

lx

STACK

RETROREFLECTOR

MODULE

lt

3. A “Saving Lx/Lt” message displays while
the system updates. Once the value is saved,
the system returns to the LX/LT sub-menu.
Verify that the read-only Lx/Lt display
reflects the change.

d. DEVICE INFO.

This sub-menu allows you to
program descriptive or pertinent user informa­tion. To access this sub-menu, select DEVICE
INFO from the BASIC SETUP menu. The menu
items for this sub-menu are explained in Table
6-11.

Use the following procedure to enter a descriptor,
tag, or message:

1. To add descriptive information, select
DESCRIPTOR, TAG, or MESSAGE from
the DEVICE INFO sub-menu. Refer to
Table 6-11 for an explanation of each
parameter type.

2. The next screen prompts you to enter the
descriptive information. Type the entry in
the highlighted area and press Enter.

lf

Figure 6-8. lx and lt Stack Dimensions

24670006

IB-106-200R

3. The system exits to the DEVICE INFO sub­menu. Verify that the parameter you modified
reflects the latest changes.

6-19

6-9. DETAILED SETUP MENU.

The DETAILED
SETUP menu is used to configure the OPM 2000R for
specific applications. To access the DETAILED
SETUP menu, select the DEVICE SETUP menu ite m
from the online menu and then select DETAILED
SETUP. Five sub-menus are available: RELAY
CONFIG, ZERO/SPAN CHECK, AVERAGES,
ALARMS, and DUST SETUP.

a. RELAY CONFIG.

The RELAY CONFIG sub­menu allows you to configure the relays to
energize upon certain alarm or status conditions. It
also allows you to view the currently selected
trigger signals. To access this sub-menu, select
RELAY CONFIG from the DETAILED SETUP
menu. The menu items in the sub-menu are
explained in Table 6-12.

NOTE

Relays 1 through 5 are normally open. Relay
6 is normally closed.

To change a default relay output setting, use the
following procedure:

1. From the RELAY CONFIG menu, select the
RELAY CONFIG menu item .

2. The next screen prompts you to select a relay
or exit. Scroll through the list, select a relay,
and press Enter.

3. At the next prompt, select one of the signal
variables from the scrollable list and press
Enter. Note that no two relays can have the
same trigger signal.

4. The display will then prompt you to configure
another relay or exit the procedure. To
configure another relay, repeat steps 2
through 4. When finished, p re ss Exit to re turn
to the RELAY CONFIG sub-menu. Verify
that the settings reflect the latest changes by
accessing the read-only displays in the sub­menu.

MENU

ITEM

Relay Config
(method)

Relay 1
(read-only)

Relay 2
(read-only)

Relay 3
(read-only)

Relay 4
(read-only)

Relay-5
(read-only)

Relay-6
(read-only)

Table 6-12. RELAY CONFIG Sub-menu.

POSSIBLE

VARIABLES DESCRIPTION

N/A Provides the relay configuration procedure by

DEFAULT

SETTING

N/A

selecting the variable that triggers each relay.

Off

Displays the currently s elected v ariable f or relay 1. Alarm 1
Sysflt (System Fault)
Span (Span Check)
Zero (Zero Check)
Flt Chk (Filter Check)
Alarm 1
Alarm 2
On

Same as Relay 1 Displays the currently selected variable for relay 2. Alarm 2

Same as Relay 1 Displays the currently selected variable for relay 3. Fltr Chk

Same as Relay 1 Displays the currently selected variable for relay 4. Zero Chk

Same as Relay 1 Displays the currently selected variable for relay 5. Span Chk

Same as Relay 1 Displays the currently selected variable for relay 6. Sysflt

IB-106-200R

6-20

b. ZERO/SPAN CHECK.

The ZERO/SPAN
CHECK sub-menu allows you to periodically
verify the operation of the unit. Zero and span
checks are required by EPA performance
specification 1, section 5.1.5, as repeated below:

“5.1.5 Simulated Zero and Upscale Calibration
System. Each analyzer must include a zero (or no
greater than 10%) opacity and an upscale opacity
value for the purpose of performing periodic
checks of the transmissometer calibration while
on an operating stack or duct. This calibration
system will provide, as a minimum, a system
check of the analyzer internal optics and all
electronic circuitry including the lamp and
photodetector assembly.”

The OPM 2000R uses a sectored Liquid Crystal
Window (LCW) to simulate an intermediate zero
and upscale calibration check value. The
individual sectors are identified in Figure 6-9.

The ZERO/SPAN CHECK sub-menu allows you
to view and configure the zero and span check
parameters. To access this sub-menu, select
ZERO/SPAN CHECK from the DETAILED
SETUP menu. Table 6-13 explains the
ZERO/SPAN menu items.

S3 S4

S2

S5

S1

24670058

Figure 6-9. Sectored LCW2

The typical values displayed in Table 6-13
exemplify a zero/span check that is performed
once a day at 2:00 a.m. SPAN VAL will assume
the span check value of 23.45% opacity for six
minutes. The zero check value will then be
output for the next six minutes. If using the
default relay setup described in Table 6-12, relay
5 is energized during the span check, and relay 4
is energized during the zero check. This function
is enabled when the blower motors are running.
Any fault condition will disable this function.

MENU

ITEM

Zero Val
(read-only)

Zero Fltr
(read, write)

Span Val
(read-only)

Span Fltr
(read, write)

Period
(read-only)

Start
(read-only)

Zero Dur
(read-only)

Span Dur
(read-only)

Zero/Span
Config (method)

Table 6-13. ZERO/SPAN CHECK Sub-menu.

POSSIBLE

VARIABLES

TYPICAL

VALUE DESCRIPTION

N/A 6.22% Displays the analog output value as a percentage

of opacity during the last zero check.

S0 through S15
(Refer to Table 6-14 for
filter descriptions.)

S14 Displays and selects the LCW sectors that

determine the nominal opacity value for zero
check. To change the variable, select ZERO
FLTR and follow the instructions on the screen.

N/A 23.45% Displays the analog output value as a percentage

of opacity during the last span check.

S0 through S15
(Refer to Table 6-14 for
filter descriptions.)

S12 Displays and selects the LCW sectors that

determine the nominal opacity value for span
check. To change the variable, select SPAN
FLTR and follow the instructions on the screen.

value within the 00:00
to 24:00 hour range

value within the 00:00
to 24:00 hour range

value within the 00:00
to 10:00 minute ran g e

value within the 00:00
to 10:00 minute ran g e

24:00 Indicates the length of time between check

cycles (in HH:MM).

02:00 Indicates the time of day the check cycle will

begin (in HH:MM).

6.00 Indicates the length of the zero check cycle (in
MM:SS).

6:00 Indicates the length of the span check cycle (in

MM:SS).

N/A N/A Provides the procedure to set the parameters for

the zero/span check.

DEFAULT

SETTING

N/A

S0

N/A

S0

00:00

00:00

00:00

00:00

N/A

IB-106-200R

6-21

The user-required span and zero check values
determine which sectors to select. Table 6-14
shows the on/off status of the sectors with each
filter check value. All values listed in Table 6-14
are nominal. What is important is that the span
check and the zero check values remain
consistent from day to day.

5. The next two screens will prompt you to
enter the span duration in minutes and
seconds, respectively. After typing each
entry in the highlighted area, press Enter.

6. At the next screen prompt, select the zero
filter from the scrollable list and press Enter.

To configure the zero/span check, use the
following procedure:

1. From the ZERO/SPAN CHECK sub-menu,
select ZERO/SPAN CONFIG.

7. In the following screen, select the span filter
from the scrollable list and press Enter.

8. Next, a “Writing zero/span configuration”
message appears as the system updates.
After configuring the zero/span check, the

2. The following two screens will direct you to
enter the zero/span period in hours and
minutes, respectively. After typing each
entry in the highlighted area, press Enter.

3. The next two screens will direct you to enter
the zero/span start time in hours and
minutes, respectively. After typing each
entry in the highlighted area, press Enter.

c. AVERAGES.

system returns to the ZERO/SPAN CHECK
sub-menu. Verify that the settings reflect the
latest changes by viewing the read-only
displays in the sub-menu.

This sub-menu allows you to
configure up to two averages of opacity,
transmittance, optical density, extinction, dust
concentration, or none (no variable specified). For
each variable, a time period is specified and the

4. The following two screens will prompt you
to enter the zero duration in minutes and
seconds, respectively, After typing each
entry in the highlighted area, press Enter.

average is calculated from the number of
measurements taken during that time period. To
access this sub-menu, select AVERAGES from the
DETAILED SETUP menu. Table 6-15 explains
the menu items in the AVERAGES sub-menu.

Table 6-14. LCW Sector Status.

LCW SECTOR

NOMINAL

FILTER
VALUE 1234

NOMINAL

OPACITY

NOMINAL

TRANSMIT-

TANCE

OPTICAL

DENSITY/

EXTINCTION

S0 OFF OFF OFF OFF 99.9 0.1 3.000
S1 OFF OFF OFF ON 93.3 6.7 1.174
S2 OFF OFF ON OFF 86.6 13.4 0.873
S3 OFF OFF ON ON 80.0 20.0 0.699
S4 OFF ON OFF OFF 73.3 26.7 0.574
S5 OFF ON OFF ON 66.6 33.4 0.477
S6 OFF ON ON OFF 60.0 40.0 0.398
S7 OFF ON ON ON 53.3 46.7 0.331
S8 ON OFF OFF OFF 46.6 53.4 0.273
S9 ON OFF OFF ON 40.0 60.0 0.222
S10 ON OFF ON OFF 33.3 66.7 0.176
S11 ON OFF ON ON 26.6 73.4 0.134
S12 ON ON OFF OFF 20.0 80.0 0.097
S13 ON ON OFF ON 13.3 86.7 0.062
S14 ON ON ON OFF 6.6 93.4 0.030
S15 ON ON ON ON 0.0 100.0 0.000

IB-106-200R

6-22

To configure an average, use the following
procedure:

1. From the AVERAGES sub-menu, select the
average you wan t to configure.

2. The next screen prompts you to configure
either the variable type or the time period of
the selected average. Select VAR.

4. Next, select PER to configure the time period
of the selected average.

5. At the prompt, select one of the time periods
from the scrollable list and press Enter. To
exit the screen without making a selection,
press Esc.

MENU

ITEM

Average 1
Average 2
(read-only)

Avg X
Variable
(read-only)

Avg X
Period
(read-only)

3. At the prompt, select one of the variables
from the scrollable list and press Enter. To
exit the screen without making a selection,
press Esc.

Table 6-15. AVERAGES Sub-menu.

POSSIBLE

VARIABLES

TYPICAL

VALUE DESCRIPTION

N/A N/A Displays the curren t av erag e v alue. Selectin g

None
Opacity

Opacity

(for Avg 1)
Transmittance
Optical Density
Extinction
Dust Concentration

15 sec

6 min. Displays the time period during which the
1 min.
2 min.
3 min.
4 min.
5 min.
6 min.
10 min.
12 min.
15 min.
20 min.
30 min.
60 min.

6. To configure another average, repeat steps 1
through 5. Once all desired averages are
configured, press Send to send the average
configurations to the intelligent electronics.

each average displays the v ariable type and the
time period of that average.

Displays the type of variable specified for the
average calculation.

variable measuremen ts are collected.

DEFAULT

SETTING

N/A

None

15 sec

IB-106-200R

6-23

d. ALARMS.

This sub-menu allows the
configuration of two alarms. Through the relay
outputs, each alarm can indicate when a variable is
not within range. In the default system setup,
alarms 1 and 2 control relay outputs 1 and 2,
respectively. To access this sub-menu, select
ALARMS from the DETAILED SETUP menu.
The nine available menu items are explained in
Table 6-16.

Alarm configuration is flexible. However, the
alarms are normally configured for high values of
opacity or opacity averages. Use the following
procedure to configure the alarm s:

1. From the ALARMS sub-menu, select
ALARM CONFIG.

3. The next screen prompts you to select the
alarm 1 type. Select one of the variables from
the scrollable list and press Enter.

4. At the alarm 1 setpoint prompt, type the new
value in the highlig ht ed f ield an d pres s En ter.

5. At the alarm 1 deadband prompt, type the
new value in the highlighted field and press
Enter.

6. Repeat steps 2 thr ough 5 to configure alarm

2.

2. The next screen prompts you to select the

MENU

ITEM

Alarm
Configuration
(method)

Alarm 1
Alarm 2
(read-only)

Alarm 1 Type
Alarm 2 Type
(read-only)

AL1 Setpoint
AL2 Setpoint
(read-only)

AL1 Deadband
AL2 Deadband
(read-only)

7. After configuring both alarms, the system

Alarm 1 setting. Select one of the variables
from the scrollable list and press Enter.

returns to the ALARMS sub-menu. Verify
that the settings reflect the latest changes.

Table 6-16. ALARMS Sub-menu.

POSSIBLE

VARIABLES

TYPICAL

VALUE DESCRIPTION

N/A N/A Provides the procedure to change the alarm

configurations.

None

Opacity Identifies the variable to monitor. None
Opacity
Transmittance
Optical Density
Extinction
Dust Concentration
Lx/Lt
Avg 1 through 12

High
Low
None

High Identifies which end of the variable range to monitor. For

example, if a high alarm type is selected, the alarm will
activate if the variable exceeds the alarm setpoint. If a
low alarm type is selected, the alarm will activate if the
variable falls below the alarm setpoint. Selecting none
will not configure an alarm.

XXX.XX% 100.00% Identifies the high or low limit of the v ariable, dependin g

on the alarm type setting.

X.XX% 1.0% Represents the valu e that must be subtracted from the

setpoint before the alarm w ill deactiv ate. For a h ig h
alarm, the variable will activate the alarm if its value
exceeds the alarm setpoint. The alarm will not deactivate
until the variable value drops below the alarm setpoint
minus th e deadban d. The deadban d is des i g n ed t o
prevent a chattering alarm.

DEFAULT

SETTING

N/A

None

0

0

IB-106-200R

6-24

Table 6-17. DUST SETUP Sub-menu.

MENU ITEM

Dust C (read-only)
Dust K (read-only)
Date (read-only)

Time (read-only)

Dust Configuration
(method)

e. DUST SETUP.

menu enable the unit for dust concentration
measurements. To access this sub-menu, select
DUST SETUP from the DETAILED SETUP
menu. The five available menu items are
explained in Table 6-17.

After iso-kinetic sampling has occurred and data
has been plotted for the c and k values, c and k
can be entered as constants.

Use the following procedure to enter the values
needed to relate extinction readings to the dust
concentration (DC).

1. From the DUST SETUP sub-menu, select
DUST CONFIGURATION.

TYPICAL

DEFAULT

VALUE DESCRIPTION

0.400 Offset constant determined by gravim etric s ampling. 0

66.800 Gain constant determined by gravimetric sam pling. 0
09/30/97 Records w h en th e du s t con s tan t s were last changed

N/A
(MM/DD/YY). The system automatically updates this
parameter.

14:32 Records when the dust constants were last changed (HH:MM).

N/A
The system automatically updates this parameter.

N/A Provides the procedure to change the dust constants. N/A

The menu items in this sub-

Table 6-18. REVIEW Menu.

SUB-MENU DESCRIPTION
IG-1 S/W Version

(read-only)

Identifies the revision level and
release date of the IG-1 software.
The revision date includes the
year, month, day, hour, and
minute.

Stack S/W Version
(read-only)

Identifies the revision level and
release date of the stack software.
The release date includes the
year, month, day, hour, and
minute.

Serial Numbers
(read-only)

Displays the serial number of the
OPM 2000R system.

SETTING

2. The next screen prompts you to enter the
dust C constant. Type the new value in the
highlighted field and press E nter.

3. The next screen prompts you to enter the
dust K constant. Type the new value in the
highlighted field and press E nte r.

4. A “Writing dust constants” message appe ars
as the system updates. Then, the system
returns to the DUST SETUP sub-menu.
Verify that the constants and date and time
reflect the latest changes.

6-10. REVIEW MENU.

The RE VI EW me nu su mmar iz es
the revision information for both the IG-1 software
and the stack software and displays the OPM 2000R
system serial number. To access this menu, select the
DEVICE SETUP from the online menu and select
REVIEW. The three available sub-menus are
explained in Table 6-18.

6-11. HART COMMUNICATOR MENU TREE FOR

IB-106-200R

6-25

OPM 2000R.

The HART menu tree shown in
Figure 6-10 identifies all of the displays and proce­dures used to monitor and control the OPM 2000R
system.

The first column in Figure 6-10 represents the online
menu. From that menu, only the DEVICE SETUP
selection subdivides into more specific menu options,
which consist of methods and/or informational
displays. A method is a procedure that you can use to
perform a specific task. If a method is not associated
with a menu option, the option will be a read-only or
read, write (editable) display.

To select a menu or menu option, either press the
right arrow action key or use the alphanumeric
keypad and press the number shown on the display
that corresponds to the menu option. For further
information about a specific menu option, refer to
paragraphs 6-6 through 6-10.

FLD DEVICE
VOLTS

Vstack
Vlamp
Vamb
Vdark

STACK
TEMPERATURE

PV OUTPUT
VARS

Vad590
Temp

PV is
PV value
% rnge
PV AO

DEVICE SETUP

PV

SV

TV

MODE

PROCESS
VARIABLES

OUTPUT
VARIABLES

VARIABLE
MAPPING

VARIABLE
RE-MAP

STATUS

SV OUTPUT
VARS

TV OUTPUT
VARS

PV is
TV is
SV is

Variable re-map
method

STATUS
GROUP 0

STATUS
GROUP 1

STATUS
GROUP 2

STATUS
GROUP 3

SV is
SV value
% rnge
SV AO

TV is
TV value
% rnge
TV AO

LON COM Status
AO1 DAC Trim

Blower Failure
Chk Optics Mode
TCVR Cal Status
Dtcr V too High
Lamp Status

Heater Status
PR SW #1 Status
LP Button Status
PR SW #2 Status
Vlamp too High
DIG IN Status

Relay 1
Relay 2
Relay 3
Relay 4
Relay 5
Relay 6

AO SATURATED

DIAG/SERVICE

(CONTINUED ON

SHEET 2)

OFFLINE CAL

REF.
VOLTAGES

TRIM DAC

LOOP TEST

(CONTINUED ON

SHEET 2)

AO FIXED

Offline Cal
method

CalDate
CalTime
Vstack0
Vlamp0
Vamb0
Vdark0
Vstack1
Vlamp1
Vamb1
Vdark1
OCRF

Trim DAC
method

LOOP TEST PV

LOOP TEST SV

LOOP TEST TV

Figure 6-10. HART Menu Tree for the OPM 2000R (Sheet 1 of 3)

AO1
AO2
AO3

AO1
AO2
AO3

Loop Test PV
method

Loop Test SV
method

Loop Test PV
method

29170019

IB-106-200R

6-26

(CONTINUED

SHEET )

FROM

1

(CONTINUED

SHEET )

FROM

1

DEVICE SETUP

PV

SV

TV

MODE

BASIC SETUP

CHECK OPTICS

FLTR CHK

SETUP CLOCK

RANGES
VALUES

LX/LT

DEVICE INFO

Check Optics
method

FILTER CHECK

FLTR CHK
VALUES

ERASE FLTR
VALUES

Date
Time

CLOCK SETUP

SELECT PV
RANGE

SELECT SV
RANGE

SELECT TV
RANGE

Lx/Lt

LX/LT SETUP

Dev id
Descriptor
Ta g
Message

Filter Check
method

Fltr Chk Values
method

Erase Fltr Values
method

Clock Setup
method

URV

LRV

URV

LRV

URV

LRV

Lx/Lt Setup
method

URV
method

URV
method

URV
method

RELAY CONFIG

Relay 1
Relay 2
Relay 3
Relay 4
Relay 5
Relay 6

zero val
zero fltr
span val
span fltr
period
start
zero dur
span dur

ZERO/SPAN
CONFIG

DETAILED
SETUP

(CONTINUED ON

SHEET )3

RELAY
CONFIG

ZERO/SPAN
CHECK

(CONTINUED ON

SHEET )3

Figure 6-10. HART Menu Tree for the OPM 2000R (Sheet 2 of 3)

Zero/Span Config
method

24670002

IB-106-200R

6-27

(CONTINUED

SHEET )

FROM

2

(CONTINUED

SHEET )

AVERAGES

FROM

2

AVERAGE 1

AVERAGE 2

Avg1Var
Avg 1 Per

Avg2Var
Avg 2 Per

DEVICE SETUP

PV

SV

TV

MODE

DETAILED
SETUP

REVIEW

ALARMS

DUST SETUP

IG-1 S/W
VERSION

STACK S/W
VERSION

SERIAL
NUMBERS

ALARM CONFIG

Alarm 1
Alarm 1 Type
Al1 Setpoint
Al1 Deadband
Alarm 2
Alarm 2 Type
Al2 Setpoint
Al2 Deadband

dust C
dust K
Date
Time

DUST
CONFIGURATION

Rev Num
Rev Year
Rev Month
Rev Day
Rev Hour
Rev Minute

Rev Num
Rev Year
Rev Month
Rev Day
Rev Hour
Rev Minute

System SN

Alarm Config
method

Dust Configuration
method

24670003

Figure 6-10. HART Menu Tree for the OPM 2000R (Sheet 3 of 3)

IB-106-200R

6-28

SECTION VII. TROUBLESHOOTING

Install all protective equipment covers
and safety ground leads after
troubleshooting. Failure to replace covers
and ground leads could result in serious
injury or death.

7-1. GENERAL.

This section covers the system mode
fault indicators generated from system self­diagnostics and provides a general troubleshooting
chart and simple test procedures to correct possible
fault conditions.

7-2. SYSTEM MODE INDICATORS.

2000R Opacity/ Dust Density Transmitter has built-in
system diagnostics features that indicate fault
conditions. These indications appear in the MODE line
of the HART communicator online menu. Normal
opacity measurement functions cannot proceed when a
system status alarm is indicated. The following modes
indicate a fault condition.

a. CALF.

This fault occurs if the last calibration

failed for any of the following voltage conditions:

The OPM

b. COMF.

This fault indicates a communication
failure caused by bad connections, faulty stack
LON board microprocessor, or corrupt stack
LON board EEPROM.

c. SYSFLT.

failure (V

This fault occurs if there is a lamp

LAMP

- V

< 1.0 VDC), blower

DARK

failure, the detector voltage is too high (V
V

> 4.75 V), or the lamp voltage is too high.

STACK

d. CALF&SYSFLT.

This fault indicates that both
a CALF and SYSFLT have occurred
independently of each other.

7-3. DIAGNOSTICS.

The OPM 2000R has a self­diagnostic feature to aid in troubleshooting. Before
troubleshooting, access the STATUS sub-menu of the
DIAG/SERVICE menu to find up-to-date, ON/OFF
indications of system status and fault conditions that
will help direct your troubleshooting efforts. Refer to
Table 7-1 for explanations of these indicators.

LAMP

or

V

STACK 0

V

LAMP 0

V

STACK 0

V

STACK 0

V

LAMP 0

V

STACK 0

V

LAMP 0

V

DARK 1

- V

- V

- V

- V

- V

LAMP 0

STACK 0

AMB 0
STACK 1

DARK 0

> 1.5 VDC
> 1.5 VDC
< 2.0 VDC
< 1.0 VDC
< 2.0 VDC
> 4.75 VDC
> 4.75 VDC
< -0.50 VDC

IB-106-200R

7-1

Table 7-1. Diagnostic Indicators .

FAULT OR

STATUS

MENU ITEM

INDICATION DESCRIPTION

STATUS GROUP 0

LON COM Status STATUS ON—LON communication problem ex is ts , su ch as bad con nection s or

signal path interference.
OFF—Normal condition.

AO1 DAC Trim STATUS ON—4-20 mA signal loop n eeds t o be cali brated.

OFF—Calibration not needed.

STATUS GROUP 1

Blower Failure FAULT ON—Blower problem exis t s .

OFF—Normal condition.

Chk Optics Mode STATUS ON—System is in the check optics mode.

OFF—Normal condition.

TCVR Cal Status STATUS ON—Transceiver n eeds to be calibrated.

OFF—Calibration is not needed.

Dter V too High FAULT ON—Measured voltage readings are > 4.75 V.

OFF—Normal condition.

Lamp Status STATUS ON—Lamp problem exists.

OFF—Normal condition.

STATUS GROUP 2

Heater Status STATUS ON—Heater is ON.

OFF—Heater is OFF.

Purge Air Flow S witch #1
(PR SW #1) Fault

Lighted Pushbutton
Pressed

Purge Air Flow S witch #2
(PR SW #2) Fault

V

too High FAULT ON—Lamp voltage is too high.

LAMP

FAULT ON—Problem exis ts with blower on tran sceiv er.

OFF—Normal condition.

FAULT ON—Pushbutton either pressed or faulty.

OFF—Normal condition.

FAULT ON—Problem exists with blower on ret roref l ect or.

OFF—Normal condition.

OFF—Normal condition.

DIG IN Status STATUS ON—Digital input is closed (on).

OFF—Normal condition.

STATUS GROUP 3

Relays 1 through 6 STATUS Indicates the ON or OFF status of each relay. Check the RELAY CONFIG

sub-menu in the DETAILED SETUP menu for the current configuration of
each relay.

AO SATURATED

AO1 through AO3 FAULT ON—Specified analog output is > 20 mA

OFF—Normal condition.

AO FIXED

AO1 through AO3 STATUS ON—System is performing a TRIM DAC or LOOP test on the indicated

analog output and the system is in the FIXED MA mode.
OFF—Normal condition.

IB-106-200R

7-2

Table 7-2. Troubleshootin g Chart.

ALARM, or other

INDICATION POSSIBLE CAUSE CORRECTIVE ACTION

1. CALF OPM 2000R faile d l a st calibr a t i on Recalibrate OPM 2000R.

2. COMF Failed communications cable Check wiring and connections between intelligent
electronics and transceiver.

COMF and stack LON

Failed microprocessor Replace stack LON board per paragraph 8-3.g.

board status LED on
COMF and stack LON

EEPROM missing or damaged Install new EEPROM.
board status LED
blinking

3. SYSFLT
Blower failure Plugged purge air filter Check filters on bottom of weather housing and

at blower intake. Clean per paragraph 8-2.d and

8-2.e, if necessary .
Faulty check valve Repair or replace check valve.
Faulty sensor tubing from air lens to purge

air failure flow switch

Ensure sensor tube connection s are airtig h t.

Check for kinks, crack s, an d pu n ctu res in th e lin e.

Repair or replace sensor tubes as needed.
Failed purge air flow switch Check that wires are properly connected. Check

blowers and air sy s tem. Replace flow s witch, if

necessary.
Blower failure Inspect blower motor an d repair or replace, if

necessary. Check circu it break er to blower motor.

Reset circuit breaker as necessary .

Detector voltage too
high (V

LAMP

or V

STACK

> 4.75 V)

Faulty detector board Adjust detector amplifier potentiometer per

paragraph 8-3.d. Perform detector test procedure

per paragraph 7-4.a. Repair or replace as

indicated.

Lamp failure
(V

- V

LAMP

1.0 VDC)

DARK

<

Faulty power supply Perform power supply test procedure per

paragraph 7-4.b. Repair or replace faulty power

supply.
Defective lamp Replace lamp per paragraph 8-3.b.

Blown LCW/lamp fuse Replace fuse per paragraph 8-5.b.
Lamp voltage too high or too low (should

be about 4.6 VDC)

Check voltage to lamp. Replace power supply if

necessary.
LCWs #1 and #2 not activating properly Perform LCW test procedure per paragraph

7-4.c. Replace LCW(s) per paragraph 8-3.f, if

necessary.
Faulty electrical connection between

detector/amplifier board and analog-to-

Check electrical cable and connection. Repair or

replace as necessary.
digital converter

Faulty analog-to-digital converter on stack

Replace stack LON board per paragraph 8-3.g.
LON board

IB-106-200R

7-3