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OPM 4000 Opacity / Dust Density Monitor Installation and Operational Manual- Rev 2.1
Manuals & Guides
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Rosemount OPM 4000 Opacity / Dust Density Monitor Installation and Operational Manual- Rev 2.1 Manuals & Guides

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Instruction Manual 2.1
OPM4001 Opacity/Dust Density Monitor Installation and Operation Manual
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Instruction Manual 2.1
Table of Content
Contents
TRANSMISSOMETER /RETRO REFLECTOR ............................................................................................................ 6
REMOTE CONTROL UNIT (RCU) ...................................................................................................................... 8
Optional Air Purge Weather Cover System ........................................................................................... 8
Alignment system .................................................................................................................................. 8
Cabling ................................................................................................................................................... 8
OPM4001 Specifications: ....................................................................................................................... 9
REGULATORY/PROCESS CONSIDERATIONS ....................................................................................................... 11
STACK EXIT CORRELATION COMPUTATIONS ..................................................................................................... 12
INSTALLATION – MECHANICAL ....................................................................................................................... 14
Installation procedure - stack flanges .................................................................................................. 14
FLANGE TO STACK INSTALLATION .................................................................................................................... 16
MOUNTING THE AIR PLENUM AND WEATHER COVERS ........................................................................................ 18
Transceiver and retro reflector assembly ............................................................................................ 19
RCU BUTTONS ............................................................................................................................................ 20
About page .......................................................................................................................................... 20
START UP VERIFYING INSTRUMENT OPERATION AND CONFIGURATION .................................................................. 22
Scrolling multiple main display pages .................................................................................................. 25
Password protected parameters ......................................................................................................... 26
Modbus Setup ...................................................................................................................................... 28
Modbus Write ...................................................................................................................................... 28
Modbus Read ....................................................................................................................................... 29
RS/485 COMMUNICATIONS AND CONNECTION ............................................................................................... 30
RS485: Pin out ...................................................................................................................................... 30
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Instruction Manual 2.1
Channel #1 and 2, 0-100% Opacity 4-20mA outputs to recording devices ......................................... 31
ALARM OUTPUT CONNECTIONS ..................................................................................................................... 32
Group 1: ............................................................................................................................................... 32
Group 2: ............................................................................................................................................... 32
ANALOG OUTPUTS 4-20MA .......................................................................................................................... 33
Other output connections possible ..................................................................................................... 34
SERVICE MODULE ........................................................................................................................................ 35
CLEAR ON STACK ZERO AND SPAN CALIBRATION ................................................................................................ 36
ZERO REFLECTOR ADJUSTMENT ...................................................................................................................... 38
Off stack zero calibration ..................................................................................................................... 39
Filter certification ................................................................................................................................ 41
Preventive/corrective maintenance schedule ..................................................................................... 42
Trouble Shooting ................................................................................................................................. 45
Trouble shooting -continued ............................................................................................................... 46
OPM4001 CONTROL UNIT DIMENSIONS ......................................................................................................... 49
OPM6142 1OF3 - WIRING .......................................................................................................................... 51
OPM6142 2OF3 - WIRING .......................................................................................................................... 52
OPM6142 3OF3 - WIRING .......................................................................................................................... 53
RS485: PIN OUT ......................................................................................................................................... 54
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Instruction Manual 2.1
Technical Support Hotline
For assistance with problems, please call the Customer Support Center (CSC).
Phone: 1-800-433-6076 1-440-914-1261
In addition to CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process Management’s field service throughout the U.S. and abroad.
Phone: 1-800-654-RMST (1-800-654-7768)
Emerson Process Management may also be reached via the Internet through e-mail and World Wide
e-mail: GAS.CSC@emerson.com
World Wide Web: www.raihome.com
World Wide Web: www.raihome.com
Warnings and Safety Guidelines for user safety and equipment protection
This manual is intended to aid trained and competent personnel in the installation of this equipment. Only a technician or engineer trained in the local and national electrical standards should perform tasks associated with the electrical wiring of this device.
Warnings
Under no circumstances will Emerson Process Management be liable or responsible for any
consequential damage that may arise as a result of installation or use of this equipment.
All examples and diagrams shown in the manual are intended to aid understanding. They do not
guarantee operation.
Emerson Process Management accepts no responsibility for actual use of this product based on
these examples.
Due to the great variety of possible applications for this equipment, the user must assess the
suitability of this product for specific applications.
Make sure to have safety procedures in place to stop any connect3ed equipment in a safe
manner if the controller should malfunction or become damaged for any reason.
Do not replace electrical parts or try to repair this product in any way. Only qualified factory trained service personnel trained in is operation should open the device’s
housing or carry out repairs.
The manufacturer is not responsible for problems resulting from improper or irresponsible use
of this device.
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Instruction Manual 2.1
You may cause an electric shock, fire or damage the equipment if you ignore any of these safety
precautions.
Manual Prepared by James F. Cognetta
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Instruction Manual 2.1
Section 1 System description
Transmissometer /retro reflector
The OPM4001 is a precision, double-pass, dual beam Transmissometer that consists of a transceiver (transmitter/receiver) mounted on one side of a stack or duct and a passive reflector mounted on the opposite side. The light source, photo detectors, and all measurement/reference optics used in opacity measurement are housed in the transceiver.
Normal mode of operation
The Dual beam measurement system has a stack mounted Transmissometer sensor system consists of an optical transceiver mounted on one side of the stack and a retro reflector mounted on the other. To avoid errors due to ambient light, the lamp (See Drawing) is electronically modulated and projects a collimated beam of light, which is split into a reference beam, and a measurement beam by an optical Beam splitter. The reference beam is directed to the reference detector, RD. The measurement beam is projected across the stack to a Retro reflector that returns the beam back across the stack to a beam splitter and directs the measurement beam to the measurement detector, MD. A portion of the returning light is also sent to the TTL (Thru the Lens) bulls-eye target viewed through a window provided at the rear of the Transmissometer. The bulls-eye is used to correct changes in alignment and is unique in that no moving parts are used!
The ratio of the measurement and reference detectors is used to provide Transmittance 2 (T 2) signal. Because the same light source is
used for both detectors, and a Measurement / Reference ratio is used throughout for the calculations, the monitor is insensitive to variations in light intensity. Since all measurements are made on a ratio basis, all resulting computations are independent of the absolute intensity of the light source or contamination of the optics associated with the collection and focusing of the energy from the lamp.
2
The (T control unit the signal is processed to read 0-100% Opacity, provide alarms and outputs.
) signal is converted to a current format and sent to the control unit for processing. At the
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Instruction Manual 2.1
Internal calibration system, zero mode
Zero and span calibration checks can be initiated manually, automatically or by a PLC or computer. During the zero calibration mode a calibrated zero reflector is placed in front of the transceiver optical package testing all optical surfaces and electronic components to assure zero point has not changed.
Internal calibration system, Span mode
In the span mode a Span filter of known Neutral Density is placed in the measurement path and produces a specific upscale reading in accordance with the latest E.P.A. requirements. The zero and span cycle provides a continuous check of all the optical components and surfaces, the main lamp, the detector, interconnecting wiring, control unit and computation analysis.
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Instruction Manual 2.1
Remote Control Unit (RCU)
The RCU provides instrument control functions, opacity readings, alarms, analog outputs, communications, system information and more. The RCU can be DIN rail mounted or panel mounted (3.7x3.7” – 93x93mm) in a control room environment and is rated NEMA 4X/IP65 when panel mounted. Battery backup for all memory is typically 7 years.
The control unit should be mounted in a control room environment i.e., clean, temperature with max/min of +0o to +50 o C (+32 o to +
o
122
F). The control unit provides instrument control functions, opacity readings, alarm and fault indicators, analog outputs, and diagnostics with contact closures.
Optional Air Purge Weather Cover System
The transceiver and reflector may be mounted in weather covers. The weather covers are fairly compact to allow movement around them even on a three­foot walkway or platform. They protect the stack-mounted components from dirt, moisture; stack temperatures within the specified ambient temperatures limits, and errant air currents around the stack.
The air purge system constantly circulates air past the optical window. The air flow is directed through the hose to an air plenum on the stack side of the optical window. The air flow in the air plenum area results in reduced pressure and increased velocity. This venturi effect tends to continually draw the air around the optical window into the purge air stream, thereby keeping the lens clean for long periods.
Alignment system
The OPM4001 includes a built-in through-the-lens alignment system. The alignment target can be viewed through a window on the transceiver. Adjustments to changes in alignment are provided by a 3­point alignment system, which is integral to the air plenum.
Cabling
The standard cabling used between the stack-mounted units and the control unit is at a minimum 6-pair, #20 AWG, twisted, shielded cable separation distance approximately 1000FT. More pairs or larger than 20 AWG is acceptable.
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Instruction Manual 2.1
Remote Control unit:
Enclosure
Panel mounted IP65/NEMA4X Dimensions 96x96x64 mm (3.8”x3.8’x2.5”).
Approvals
CE and UL Listed
Digital Display
LED backlight, Instant and Average Opacity -5 to 99% Opacity Ambient Temperature Range
0 to +50o C (+32 to + 122o F)
Power Requirements
Power 20.4 to 28.8VDC < 10% ripple, 20va
Alarm Time Delay & set point
Field programmable.
Alarm Reset
Manual or Automatic
Analog Outputs
Two 12-bit Analog outputs 4-20mA, Field selectable range -
5.0 to 100%.
Exit Correlation (Lx / Lt)
0.3~1.0 OPLR
Calibration check options
Selectable internal timed or computer initiates or push button on demand.
Communication
Remote access, RS485 MODBUS networking.
Battery Backup
7 years typical
OPM4001 Specifications:
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Instruction Manual 2.1
Transceiver/ Reflector:
Enclosure/Power Requirements
NEMA 4X watertight enclosure. Power 120 or 240VAC +/­10%, 50/60Hz. 65va for transceiver, 65va for Service module.
Path Length
2 to 50 feet (0.6 to 4.6 15.2 meters)
Optical System
Double Pass with LSEM (Light Source Electronic Modulation).
Ambient Light Immunity
Solid state LSEM (Light Source Electronic Modulation) Reflector
Type 1 (plastic) reflector assembly
Alignment Verification
Built-in through-the-lens system standard
LSEM Aging Compensation
Automatic
LSEM Expected Life
70,000 hours (Field proven for > 8 years)
Ambient Temperature Limits
-40 to +130o F (-40 to +54o C)
Process Gas
Up to 750o F (400 o C) higher available contact the factory. Mounting Flanges
3 inch IPS, 150# flange (other sizes available)
Design and performance:
Peak and Mean Spectral Response
Photopic; 515 to 585 nm, less than 10% of peak response outside the desired 400 to 700 nm region. USDEP 40 CFR 60
Angle of View
< 4.0 o from optical axis
Angle of Projection
< 4.0 o from optical axis
Calibration Error
< +2% of full scale
Response time
< 10 second
Zero Drift
< 1% (24 hours)
Calibration Drift
< 1% (24 hours)
Operational Period
6 Months
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Instruction Manual 2.1
Section 2 Installation Considerations
Regulatory/Process Considerations
The EPA has established the following guidelines for choosing an opacity/dust density monitor installation site:
1) Locate the transmitter across a section of a duct or stack that will provide a particulate
matter flow through the path of the transmitter beam representative of the duct or stack flow.
2) Ensure the transmitter location is down-stream from all particulate control equipment.
3) Locate the transmitter as far from bends and obstructions as practical.
4) If a transmitter is to be located less than 4 duct diameters downstream from a bend, install
the transmitter in the plane defined by the bend, as shown in the figure below.
5) Ideally, locate the transmitter eight to ten stack diameters upstream from the stack exit
and three to five diameters downstream from any bends, junctions, or other constrictions in the stack or duct.
For best results, mount the transceiver and retro reflector modules so the light beam is exactly perpendicular to the stack or duct and the beam goes through the center. Do not install the transmitter downstream of a wet scrubber. The water droplets introduced to the gas stream by such equipment will interfere with the opacity readings. For an accurate measurement under these conditions, choose a location upstream from a wet scrubber or a location downstream from the scrubber where the water droplets are vaporized by the reheating of the gas. The stack exit correlation is especially important to verify. If possible all dimensions should be verified by actual measurements. Measure and record inside stack dimensions at the measuring point and at the stack exit, and compute the Optical Path Length Ratio (O.P.L.R.). Check that the calculated and the O.P.L.R. found in the Factory OPLR Check step found further in this section are within +/- 2%.
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Instruction Manual 2.1
Lt
Lx
OPLR*2
50.0
120*2
120
OPLR
Stack Exit Correlation Computations
NOTE: The stack exit correlation is especially important to verify. If possible, all dimensions should be verified by actual measurements. Using the instructions below verify that the values are correct as displayed in the About page. Lx/Lt is the ratio of the inside diameter at the top of the stack to the inside diameter of the stack where
the instrument is located. If the ratio is greater than 1.0, the exit opacity will be greater than the opacity at the instrument location. The OPM4001 uses this correction factor to calculate the stack exit opacity. It is not practical to have an Lx/Lt factor much greater than 2.0 because the error of the instrument increases as Lx/Lt becomes greater.
Lx = inside stack diameter at stack exit.
Lt = inside stack diameter at the transmitter location.
Lf = flange to flange distance between the transceiver and retro reflector unit.
1) Measure and record Lx and Lt and compute the Optical Path Length Ratio (OPLR).
2) Check that the calculated value and the
OPLR found in the 2nd About page are within ±2%.
3) Example: A stack with a 120 in. (3048 mm)
stack exit ID and a 120 in. (3048 m) path length.
4) Enter the exit
diameter (Lx) and measured diameter (Lt) in the control unit. Refer to Section 4: Operation, for info on using the control unit.
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Instruction Manual 2.1
Choose an installation site; the primary considerations for choosing a site for the OPM4001 are accessibility, ambient environmental conditions, and locating the unit to obtain a representative sample of the process. Review the excerpt from the Federal Register in appendix for suggestions before selecting an installation site. The following general guidelines should also be considered.
Sensors height from Platforms, walk way/ decks, etc, A platform or walkway must be available for access to the weather covers. The optimum condition would have the mounting flanges and weather covers approximately 5 feet up from the floor. Railings and other obstructions should allow the weather cover to swing clear as shown in the installation drawings.
Locate the stack-mounted units in an area with ambient temperatures between -4 o to +130o F. (Consult the factory for other temperature ranges.) Areas that are clean and dry are desirable. Avoid areas with condensation.
Maintenance intervals are directly related to the installation environment. Intervals can vary from 2 to 3 months in fairly clean environments, to twice a month in dirty environments. Lens cleaning is a function of the ambient conditions and cleanliness of the purge air.
Locate the instrument to avoid excessive vibration or shock.
Locate the control unit in an easily accessible area with
temperatures between +32o to 122o F. To permit the
operator to read and/or change controls, the unit should not be mounted higher than five feet from floor level.
Stack exit, Locate the transceiver more than two stack diameters down from the stack exit is recommended.
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Instruction Manual 2.1
Installation – Mechanical
A review of the drawings and procedures provided will help to produce an error free installation. However, there are important additional points that must be observed. The beam of the instrument
must be kept in the horizontal plane; the transceiver cannot be rotated more than +/- 10 o from vertical. The weather covers must be installed vertically plumb.
Installation and wiring diagrams are found at the end of this manual. Please review all drawings prior to starting installation or wiring. If you have any questions please contact our Customer Support Center (CSC) Phone: 1-800-433-6076 or 1-440­914-1261
E-mail: GAS.CSC@emerson.com
Installation procedure - stack flanges
For an opacity monitor, the customer is required to supply and install two 3" I.P.S. flanges at eye level directly across from each other. The flange faces, mounted on pipe stubs, should be approximately 6" to 8" from the stack or insulation. On completion of the installation, the flanges must be aligned so that the total deviation of the light source flange relative to a common centerline,
does not exceed +1o and the retro reflector flange does not exceed +3o .
Flanges should be mounted approximately 5 feet up from the deck of platforms, roof or walk way.
At installations where conditions permit, this may be accomplished by using a piece of 2 1/2" pipe suspended across the stack protruding far enough to allow slipping the 3" flange pipe assemblies over each end and welding in place as shown on the following page.
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Instruction Manual 2.1
Any deviation up to the previously specified limits can be adjusted out during the installation and alignment of the light source and retro reflector with the system's alignment adjustments.
Where installations do not permit the use of the aforementioned method, the following procedure will accomplish the same results. (See drawing EMS1002. An alignment tool can be purchased from the factory to insure accurate alignment.
Accurately locate one 3 1/2" diameter hole (large enough to accept the 3" pipe) and the other hole approximately 1/2" diameter, directly across from each other. Attach the alignment tool to the flange/pipe assembly and insert the pipe into the 3 1/2" hole in the stack wall. Align the assembly with the 1/2" diameter hole on the opposite side by viewing through the alignment tool and weld the pipe in place. Care must be exercised when welding to maintain alignment.
The 1/2" diameter hole should now be enlarged approximately 3 1/2" to accept the other flange/pipe assembly. Proceed in the same manner, installing the assembly with the alignment tool attached, and weld in place maintaining concentric alignment with the 3" pipe previously installed on the opposite wall.
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Instruction Manual 2.1
Flange to stack installation
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Instruction Manual 2.1
Air purge/Weather cover mechanical Installation
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