Rosemount OPM 3000 Opacity / Dust Density Monitor-Rev 1.1 Owner's manual

Brand: Rosemount

Model: OPM 3000 Opacity / Dust Density Monitor-Rev 1.1

Type: Owner's manual

http://www.raihome.com

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

Opacity/Dust Density Monitor

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HIGHLIGHTS OF CHANGES

Effective August 31, 2006 Rev 1.0

Page Summary

General Revised and removed the figures from Section 8, Drawings, and relocated them in their

applicable sections. Changed all references of the Micro-turn 200 to read as the Zero Jig.

Page 1-1 Added information under Component Checklist.

Page 1-1 thru 1-3 Added General information under System Overview.

Page1-2 thru 1-3 Added Figure 1-1, Typical System Package (Sheet 1 and 2).

Page 1-4 Added Figure 1-2, Transceiver Assembly with Weather Cover.

Page 1-6 thru 1-7 Updated Tables 1-1 and 1-2 to represent current conditions.

Page 2-1 Added the bulleted list under Overview.

Page 2-2 Added Clearance and Sample Area headings along with descriptive text.

Page 2-3 Added Figure 2-1, Installation Clearances and Weather Cover Dimensions.

Page 2-4 Added information and procedural steps under Regulatory Process Consideraions, along

with Figure 2-2, Transmitter Location.

Page 2-5 thru 2-6 Organized information under Installation of Stack Flanges into procedural steps.

Converted important installation reminders from body text into the five Notes.

Page 2-7 Added Figure 2-3, Mounting the Stack Flanges.

Page 2-8 Added Figure 2-4, Stack Flange Installation.

Page 2-9 Revised and streamlined information for Mounting the Air Plenum and Weather Covers.

Page 2-10 Updated Figure 2-6, Air Plenum to better illustrate its assembly. Added Attach Blower

heading and step 1.

Page 2-11 Added Note regarding the installation procedures for the transceiver and retro reflector.

Added information and procedural steps under Mounting the Control Unit.

Page 2-12 Added Figure 2-8, Mounting Brackets, and Figure 2-9 Control Unit Installation.

Page 2-13 Added procedural steps under System Wiring Installation.

Page 2-14 Added Figure 2-10, Electrical Installation.

Page 2-15 Updated procedural steps under Beam Alignment Procedure. Revised Figure 2-11,

Alignment of the Transceiver.

Page 2-16 Moved Ouput Connections from Section 4.

Page 3-1 Added the Caution and information under Overview.

Page 3-2 Added Stack Exit Correlation Computation information and Figure 3-1, Lx and Lt Stack

Dimensions.

Page 3-3 thru 3-4 Organized information under First Time Adjustment and Calibration Procedures into

procedural steps. Revised Figure 3-2, Zero and Span Adjustments to better illustrate the

locations of PT-1 and PT-3.

HIGHLIGHTS OF CHANGES (CONTINUED)

Effective August 31, 2006 Rev 1.0 (Continued)

Effective January, 2007 Rev 1.1

Page Summary

Page 4-1 Added bulleted list under Overview.

Page 4-1 thru 4-3 Organized information under Main Display Screens into procedural steps.

Page 4-4 Revised format to display information in procedural steps.

Page 5-1 thru 5-6 Added Section 5, Zero Jig and Neutral Density Filter.

Page 6-1 Added Overview information.

Page 6-1 thru 6-2 Revised Preventive Maintenace Schedule.

Page 6-3 thru 6-6 Added Corrective Maintenance procedural steps for the lamp/bulb, transceiver fuse, and

circuit boards. Added Figures 6-1 thru 6-4.

Page 7-1 Added Caution, and revised Troubleshooting table to include references.

Page Summary

Cover Added picture of control unit to the cover photo.

Page 1-4 Added picture of control unit to Figure 1-2, Transceiver Assembly with Weather Cover.

Page 1-5 Revised the TTL Bulls-Eye on Figure 1-3, Component Relationships.

Page 1-7 Added Code 03 under Weather Cover and Blowers.

Page 2-9 Removed Figure 2-5, Transceiver and Hinge Pins.

Page 2-10 Added information on how to attach a single or dual blowers. Added callouts to Figure 2-6,

Air Plenum.

Page 2-15 Revised the Beam Alignment Procedure. Replaced Figure 2-11, Alignment of the

Transceiver.

Page 5-3 Revised logo on the zero jig, and added the note to Figure 5-2, Zero Jig Installation.

Page 6-6 Added the note to Figure 6-4, Power/Modulator Board Replacement.

Page 8-1 Revised Section 8, and aded two new spare parts.

Page A-2 thru A-24 Added note 11 to the safety data section. Added new language translations.

Page B-1 Updated the return of materials address.

Back Cover Updated the address blocks.

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

http://www.raihome.com

Table of Contents

Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -i

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -ii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -ii

Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -ii

SECTION 1

Description and

Specifications

Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

OPM 3000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Normal Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SECTION 2

Installation

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

Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Choose an Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Sample Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Stack Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Regulatory/Process Considerations . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Installation of Stack Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Mounting the Air Plenum and Weather Covers . . . . . . . . . . . . . . . 2-9

Attach Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Mounting the Transceiver and Retro Reflector. . . . . . . . . . . . . . . 2-11

Mounting the

Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

System Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Beam Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Channel #1, 0-100% Opacity 4-20 mA Output to Recording Devices2-16

Channel #2, 4-20 mA Output to Recording Devices. . . . . . . . . . . 2-16

Alarm Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Early Warning Alarm Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

SECTION 3

Startup and Calibration

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Before Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Startup Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Stack Exit Correlation Computation . . . . . . . . . . . . . . . . . . . . . . . . 3-2

First Time Adjustment and Calibration Procedures . . . . . . . . . . . . . . . 3-3

Clear On Stack Zero and Span Calibration . . . . . . . . . . . . . . . . . . 3-3

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

TOC-2

SECTION 4

Normal Operation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Main Display Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Setup of Password Protected Perimeters. . . . . . . . . . . . . . . . . . . . 4-4

Off Stack Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

SECTION 5

Zero Jig and Neutral

Density Filter

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Using the Zero Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Coarse Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Filter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Filter Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

SECTION 6

Maintenance

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

Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Transceiver Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Circuit Board Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

SECTION 7

Troubleshooting

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

SECTION 8

Spare Parts

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

OPM 3000 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . 8-1

APPENDIX A

Safety Data

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

APPENDIX B

Returning Equipment to

the Factory

Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

http://www.raihome.com

OPM 3000 Opacity/Dust Density Monitor

ESSENTIAL

INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Emerson Process Management designs, manufactures and tests its products

to meet many national and international standards. Because these

instruments are sophisticated technical products, you MUST properly install,

use and maintain them to ensure they continue to operate within their

normal specifications. The following instructions MUST be adhered to

and

integrated into your safety program when installing, using, and maintaining

Emerson’s Rosemount Analytical products. Failure to follow the proper

instructions may cause any one of the following situations to occur: Loss of

life; personal injury; property damage; damage to this instrument and

warranty invalidation.

• Read all instructions

prior to installing, operating and servicing the

product.

• If you do not understand any of the instructions, contact your

Emerson Process Management representative for clarification.

• Follow all warnings, cautions and instructions

marked on and

supplied with the product.

• Inform and educate your personnel in the proper installation,

operation and maintenance of the product.

• Install your equipment as specified in the Installation Instructions

of the appropriate Instruction Manual and per applicable local and

national codes. Connect all products to the proper electrical and

pressure sources.

• To ensure proper performance, use qualified personnel

to install,

operate, update, program, and maintain the product.

• When replacement parts are required, ensure that qualified people use

replacement parts specified by Emerson Process Management.

Unauthorized parts and procedures can affect the product's

performance, place the safe operation of your process at risk, and

VOID YOUR WARRANTY. Look-alike substitutions may result in fire,

electrical hazards or improper operation.

• Ensure that all equipment doors are closed and protective covers

are in place, except when maintenance is being performed by

qualified persons, to prevent electrical shock and personal injury.

The information contained in this document is subject to change without

notice.

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

PREFACE The purpose of this manual is to provide information concerning the

components, functions, installation and maintenance of the OPM 3000.

Some sections may describe equipment not used in your configuration. The

user should become thoroughly familiar with the operation of this module

before operating it. Read this instruction manual completely.

DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS and NOTES found

throughout this publication.

NOTE

Highlights an essential operating procedure, condition, or statement.

SYMBOLS

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a

manual illustration number. It is not a part number and is not related to the

illustration in any technical manner.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not

strictly observed, could result in injury, death, or long-term health hazards of personnel.

Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not

strictly observed, could result in damage to or destruction of equipment, or loss of

effectiveness.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETI

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

http://www.raihome.com

Section 1 Description and Specifications

Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-6

COMPONENT

CHECKLIST

A typical Rosemount Analytical OPM 3000 Opacity/Dust Density Monitor

should contain the items shown in Figure 1-1. Sheet 1 shows the assembly on

the transceiver side, and sheet 2 shows the assembly on the retro reflector

side. Items on the mounting panel are factory installed and come as shown.

Figure 1-2 shows the transceiver assembly with the optional stainless steel

weather cover.

Due to the availability of optional accessories, the system package will vary.

Use the product matrix, in Table 1-2, to compare your order number against

your unit. The first part of the matrix defines the model. The last part defines

the various options and features of the OPM 3000. Ensure the features and

options specified by your order number are on or included with the unit.

SYSTEM OVERVIEW

General The OPM 3000 Opacity/Dust Density Monitor provides continuous, low

maintenance, precision measurement of opacity and optical density in

industrial applications. It is a cost-effective instrument that serves as an aid in

operating pollution and/or process control equipment.

Opacity refers to the amount of light being scattered or absorbed by particles

in the light beam path. An opacity or dust density transmitter (also called a

transmissometer) measures the particulate level of stack emissions. One of

the most common reasons for measuring opacity is to comply with

Environmental Protection Agency (EPA) or other national requirements.

Federal regulations for new emission sources and many state regulations for

both new and existing sources specify maximum limits for stack emission

opacity.

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.

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

1-2

Figure 1-1. Typical System Package (Sheet 1 of 2)

38440032

OPM

3000

ESC

Model:

Serial:

OPM

3000

Opacity/Dust Density

Monitor

tio

-1

-3

1. Control Unit

2. Zero Jig

3. Mounting Plate

4. Instruction Manual

5. Air Blower

6. Air Filter

7. Air Hose with Clamps

8. Duplexer

9. Transceiver with

Air Plenum attached

Note: The optional weather

covers are not shown

in the typical system

package.

10. Terminal Board

Instruction Manual

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January 2007

1-3

OPM 3000

Figure 1-1. Typical System

Package (Sheet 2 of 2)

Opacity data can also serve as a rough indicator of combustion efficiency.

Extreme changes in opacity may indicate inefficient combustion or boiler

problems. Because the transmitter gives accurate, immediate response data,

corrective actions can be taken as soon as problems occur. This data serves

not only the compliance requirement of pollution regulation standards but also

as a means to achieve improved efficiency and operating profit.

Originally, a trained smoke reader determined the particulate level of stack

emissions solely by observation. The opacity of the plume was judged in

reference to a standard Ringelmann scale of 0 to 5. These determinations

tended to be influenced by several sources of error such as sky haze, sun

position, and the subjective determination of the observer. These sources of

error, especially at lower opacity levels, can produce highly variable readings

even when performed by a trained observer.

OPM 3000 System

Features

Transmissometer/Retro Reflector

The OPM 3000 is a precision, double-pass, dual beam Transmissometer that

consists of a transceiver (transmitter/receiver) mounted on one side of a stack

or duct and a passive reflector mounted on the opposite side. The light

source, photo detectors and all measurement/reference optics used in opacity

measurement are housed in the transceiver.

The function of the reflector is to return the measurement beam to the

detector in the transceiver, creating a double pass across the process stream.

The standard reflector is used for measurement path lengths up to 15 feet

(4,6 m). For longer path lengths, maximum 60 feet (18,3 m), reflectors, optical

parts and electronics will vary.

38440041

Notes: 1. Install air hose from the blower tee on

the transceiver assembly.

2. The optional weather covers are not

shown in the typical system package.

1. Mounting Plate

2. Retro Reflector with

Air Plenum attached

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

1-4

Figure 1-2. Transceiver

Assembly with Weather Cover

Control Unit

Mounted in a control room environment, the OPM 3000 control unit provides

instrument control functions (Section 4: Normal Operation for details).

Optional Air Purge Weather Cover System

The transceiver and reflector may be mounted in weather covers. The

weather covers are fairly compact to allow movement around them even on a

three-foot walkway or platform. They protect the stack-mounted components

from dirt, moisture, stack temperatures within the specified ambient

temperatures limits, and errant air currents around the stack.

The air purge system constantly circulates air past the optical window. The

airflow is directed through the hose to an air plenum on the stack side of the

optical window. The airflow in the air plenum area results in reduced pressure

and increased velocity. This venturi effect tends to continually draw the air

around the optical window into the purge air stream, thereby keeping the lens

clean for long periods.

Alignment System

The OPM 3000 includes a built-in through-the-lens alignment system. The

alignment target can be viewed through a window on the transceiver.

Adjustments to changes in alignment are provided by a 3-point alignment

system, which is integral to the air plenum.

Cabling

The standard cabling used between the stack-mounted units and the control

unit is at a minimum 2-pair, #22 AWG, twisted, shielded cable. More pairs or

larger than 20 AWG is acceptable.

38440039

Transceiver

Filter

Air Blower

Mounting

Plate

Duplexer

Weather

Cover

Control Unit

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

1-5

OPM 3000

Normal Mode of

Operation

The dual beam measurement system has a stack mounted transmissometer

sensor system that consists of an optical transceiver mounted on one side of

the stack and a retro reflector mounted on the other (Figure 1-3). To avoid

errors due to ambient light, the lamp is electronically modulated and projects

a collimated beam of light, which is split into a reference beam, and a

measurement beam by an optical beam splitter. The reference beam is

directed to the reference detector (RD). The measurement beam is projected

across the stack to a retro reflector that returns the beam back across the

stack to a beam splitter and directs the measurement beam to the

measurement detector (MD). A portion of the returning light is also sent to the

TTL (Thru The Lens) bulls-eye target viewed through a window provided at

the rear of the transmissometer. The bulls-eye is used to correct changes in

alignment and is unique in that no moving parts are used.

The ratio of the measurement and reference detectors is used to provide a

transmittance

) signal. Because the same light source is used for both

detectors, and a measurement / reference ratio is used throughout for the

calculations, the monitor is insensitive to variations in light intensity. Since all

measurements are made on a ratio basis, all resulting computations are

independent of the absolute intensity of the light source or contamination of

the optics associated with the collection and focusing of the energy from the

lamp. The (T

) signal is converted to a current format and sent to the control

unit for processing. At the control unit the signal is processed to read 0-100%

opacity, and provide alarms and outputs.

Figure 1-3. Component

Relationships

RD MD

Aperture P

Main Lamp

TTL Bulls-Eye

Projection Lens

Retro Reflector

Aperture V

38440001

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January 2007

OPM 3000

1-6

SPECIFICATIONS Specifications for the OPM 3000 system are listed in Table 1-1.

Table 1-1. OPM 3000

Specifications

OPM 3000 Specifications

Control Unit

Enclosure Panel mounted IP65/NEMA 4X Dimensions 3.8 in. x 3.8

in. x 2.5 in. (96 x 96 x 64 mm). Power 20.4 to 28.8VDC

< 10% ripple, 400 mA.

Digital Display LED backlight

Ambient Temperature Range +32 to +122

F (0 to +50

Power Requirements 24 VDC

Alarm Time Delay and Set Point Field programmable, 10 pnp (source) outputs 24 VDC;

optional relays available.

Alarm Reset Manual or Automatic

Analog Outputs Two 12-bit Analog outputs: 4-20 mA, 0-10 VDC

OPLR/Exit Correlation

(Lx / 2*Lt)

0.2 to 3.0

Calibration Check Options Manual zero and span calibrate with dedicated zero

reflector or Zero with clear stack condition.

RS485 Two Ports each Modbus or RS485 networking

I/O Expansion Port Up to 128 additional I/O

Battery Back 7 years typical

Transceiver/Reflector

Enclosure NEMA 4 watertight enclosure. Power 120/240 VAC,

50/60 Hz

Path Length 3 feet to 53 feet (0.9 to 15.9 meters)

Optical System Double Pass

Reflector Type 1 (plastic) reflector assembly

Light Source Aging

Compensation

Automatic

Light Source Life 45,000 hours (>5 years)

Ambient Temperature Limits -40 to + 130

F (-40 to +54

Process Gas Up to 750

F (400

Alignment Verification Built-in through-the-lens system standard

Mounting Flanges 3 inch IPS, 150 lb flange, standard

Ambient Light Immunity Solid-state electronic light modulation

Wiring 2 pair twisted shielded cable, 22 AWG

Design and Performance

Peak and Mean Spectral

Response

Photopic; 515 to 585 nm less than 10% of peak

response outside the desired 400 to 700 nm region.

Angle of View <4.0

from optical axis

Angle of Projection <4.0

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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January 2007

1-7

OPM 3000

Table 1-2. Product Matrix

OPM 3000 OPACITY DUST DENSITY MONITOR - ORDERING INFORMATION

Select complete model number from the Product Matrix

OPM3000 Opacity/Dust Density Monitor Non-compliant

Code Intelligent Electronics

01 Basic Unit – Digital Display, (2) 4-20 mA Outputs, (4) Alarm PNP’s, RS 232/485, Modbus

Code Transceiver and Path Length

11 3-15’ Path Length

12 >15-21’ Path Length

13 >21-40’ Path Length

14 >40-53’ Path Length

Code Weather Cover and Blowers

00 None

01 Weather Covers and Single Blower/Tee

02 Weather Covers Only

03 Weather Covers and Dual Blowers

Code Zero Jig Type

00 None

01 Zero Jig and a 84% Neutral Density Filter

Code Dust Calculation

01 None

02 With Dust Calculation (mg/m

)

OPM30000112020001 Example

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

1-8

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

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Section 2 Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1

Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . page 2-2

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5

System Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13

Beam Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . page 2-15

Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-16

OVERVIEW This section describes:

• Considerations prior to installation.

• Mechanical installation procedures, including the applicable drawings

and pictures to assist in the process.

• Wiring schematics for the OPM 3000 system.

• The beam alignment procedure.

• Output connections for alarms and recording devices.

Before installing this equipment, read the “Safety instructions for the wiring and installation

of this apparatus” in Appendix A. Failure to follow safety instructions could result in serious

injury or death.

Install all protective equipment covers and safety ground leads after installation. Failure to

install covers and ground leads could result in serious injury or death.

Before making any electrical connections, make sure the AC power supply is first switched

off. Failure to do so could cause personal injury or even death. Make sure that the voltage

and frequency of the AC supply match the designations on the analyzer component tags.

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

2-2

INSTALLATION

CONSIDERATIONS

Choose an Installation

Site

The primary considerations for choosing a site for the OPM 3000 are

accessibility, ambient environmental conditions, and obtaining a

representative sample of the process. The following general guidelines should

be considered.

Accessibility Locate the instrument where it will provide safe access for periodic

maintenance and inspection. A platform or walkway is required for access to

the sensors and weather covers. The optimum condition is to have the

mounting flanges and weather covers approximately 5 feet (1,5 m) above the

floor. A minimum of 12 in. (305 mm) from the bottom of the weather cover to

the floor is required in order to remove the air filters.

Clearance Installation clearances for the transceiver, retro reflector and optional weather

covers are shown in Figure 2-1.

Environment Locate the stack-mounted units in an area with ambient temperatures

between -40

to +130

F (-40

to 54

C). (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.

Choose a location that will minimize excessive vibration or shock.

Locate the control unit in an easily accessible area with temperatures

between +32

to 122

F (0

to 50

C). To permit the operator to read and/or

change controls, the unit should not be mounted higher than five feet from

floor level.

Sample Area To achieve a representative sample, the accepted practice is to have the

measurement path of the instrument directly in the center of the stack. An

area should be chosen where the gases are not stratified in the stack or duct.

When installed near a bend, install the transceiver in the plane defined by the

bend; refer to "Regulatory/Process Considerations". Avoid locations where

large amounts of condensed water is present.

Stack Exit It is recommended to locate the transceiver at least two stack diameters from

the stack exit.

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

2-3

OPM 3000

Figure 2-1. Installation Clearances and

Weather Cover Dimensions

38440021

Minimum Swing

Clearance

34 in. (863,6 mm)

From Flange Center

Cover In Upright Position

60 in.

(1524 mm)

21.00 in. (533 mm)

(2) Covers

GAS FLOW

30.5 (775 mm)

(3) Covers

VERTICAL

AXIS

Leave 3 in.

(76 mm)

clearance from

flange face

for swinging.

Stack or Breeching

Wall OD

RETRO

TRANSCEIVER

12.250 in.

(311 mm)

6.125 in.

(156 mm)

6to8in.

(152 to 203 mm)

TOP VIEW *

6to8in.

(152 to 203 mm)

6.125 (156 mm)

7.5 in.

(191 mm)

SIDE VIEW **

*Note 1:

**Note 2:

The top view represents the transceiver and retro reflector assemblies

with their swing clearances. Optional weather covers are not shown.

The side view represents the installation and swing clearance

dimensions for the optional weather covers.

Optional Weather

Cover

Optional Weather

Cover

PLATFORM

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

OPM 3000

2-4

Regulatory/Process

Considerations

The EPA has established the following guidelines for choosing an opacity/dust

density monitor installation site:

1. Locate the transmitter across a section of a duct or stack that will

provide a particulate matter flow through the path of the transmitter

beam representative of the duct or stack flow.

2. Ensure the transmitter location is down-stream from all particulate

control equipment.

3. Locate the transmitter as far from bends and obstructions as practical.

4. If a transmitter is to be located less than 4 duct diameters downstream

from a bend, install the transmitter in the plane defined by the bend, as

shown in Figure 2-2.

5. Ideally, locate the transmitter eight to ten stack diameters upstream from

the stack exit and three to five diameters downstream from any bends,

junctions, or other constrictions in the stack or duct.

For best results, mount the transceiver and retro reflector modules so

the light beam is exactly perpendicular to the stack or duct and the

beam goes through the center. Do not install the transmitter

downstream of a wet scrubber. The water droplets introduced to the gas

stream by such equipment will interfere with the opacity readings. For

an accurate measurement under these conditions, choose a location

upstream from a wet scrubber or a location downstream from the

scrubber where the water droplets are vaporized by the reheating of the

gas.

Figure 2-2. Transmitter Location

Less than

4 duct

diameters

38440028

Note:

The transceiver and retro reflector are shown

with the optional weather covers installed.

Instruction Manual

IM-105-3000, Rev 1.1

January 2007

2-5

OPM 3000

MECHANICAL

INSTALLATION

NOTE

The beam of the instrument must be kept in a horizontal plane; the transceiver

cannot be rotated more than ±10

from vertical. The weather covers must be

installed vertically level.

Installation of Stack

Flanges

Mounting on stack diameters under 6 feet

NOTE

Flanges should be mounted approximately 5 feet (1,5 m) up from the deck of

the platforms, roof or walk way.

1. Form two mounting holes in the stack at locations specified in

"Installation Considerations". Holes must be on the same horizontal and

vertical axes. A liquid level can be used to ensure that modules are

installed on the same horizontal plane.

2. Insert a piece of 2-1/2 in. (64 mm) pipe through the mounting holes.

Make sure pipe is protruding far enough to allow installation of the 3 in.

pipe flange assemblies over each end (Figure 2-3, Stacks Under 6 Feet

Across).

NOTE

The customer is required to supply and install two 3 in. IPS flanges at eye

level directly across from each other.

3. The flanges must be aligned so that the total deviation of the light

source flange relative to a common centerline does not exceed ±1

and

the retro reflector flange does not exceed ±3

. Any deviation within

these limits can be countered during the installation and alignment of

the light source and retro reflector with the system's alignment

adjustments.

4. Weld the pipe flanges to the mounting nipples, as shown in Figure 2-4.

5. Install the pipe flange assemblies into the stack / duct wall. The flange

should be 6 to 8 in. (152 to 203 mm) from the stack or insulation

(Figure 2-4).

Mounting on stack diameters over 6 feet

1. Form two mounting holes in the stack at locations specified in

"Installation Considerations". Holes must be on the same horizontal and

vertical axes. A liquid level can be used to ensure that modules are

installed on the same horizontal plane.

2. Locate one 3-1/2 in. (89 mm) diameter hole (large enough to accept the

3 in. mounting nipple) and the other hole approximately 1/2 in. (13 mm)

diameter, directly across from each other.

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Rosemount OPM 3000 Opacity / Dust Density Monitor-Rev 1.1 Owner's manual

Rosemount OPM 3000 Opacity / Dust Density Monitor-Rev 1.1 Owner's manual

Rosemount OPM 3000 Opacity / Dust Density Monitor-Rev 1.1 Owner's manual

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