Rosemount OPM 4000 Opacity / Dust Density Monitor-Rev 1.3 Owner's manual

http://www.raihome.com

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

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 to 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 1-4 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 1-8 thru 1-9 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 Considerations, 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 Updated Figure 2-5, Transceiver and Retro Reflector Hinge Pins to better illustrate the

hinge pin. 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.

Page 2-12 Added Mounting the Control Unit procedural steps. Relocated Figure 2-8, Control Unit

from the end of the section.

Page 2-13 thru 2-14 Added Figure 2-9, Panel Cutout for Control Unit, and Figure 2-10 Control Unit Dimensions.

Page 2-15 thru 2-16 Added procedural steps under System Wiring Installation.

Page 2-17 Added Figure 2-11, Control Unit Terminal Identification.

Page 2-18 thru 2-19 Added Figure 2-12, Typical System Wiring (Sheets 1 and 2).

Page 2-20 Revised Figure 2-14, Service Module Switch Location. Updated procedural steps under

Beam Alignment Procedure. Revised Figure 2-15. Moved Air Flow Switch information to

Section 8, Troubleshooting.

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

HIGHLIGHTS OF CHANGES (CONTINUED)

Effective August 31, 2006 Rev 1.0 (Continued)

Effective January, 2007 Rev 1.1

Page Summary

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

Dimensions.

Page 3-3 Reformatted body text into bulleted lists and procedural steps.

Page 4-1 Added Overview and bulleted list.

Page 4-2 Reformatted body text under Alarm Set Point Adjustments and Alarm Time Delay

Adjustment into procedural steps.

Page 4-4 Reformatted body text under Auto Cal Timer Adjustment into procedural steps.

Reformatted first paragraph under Service Module into a bulleted list. Added the second

paragraph, along with the normal operation conditions.

Page 5-1 Added Overview and bulleted list.

Page 5-2 Changed the Procedure heading to Installation, and renumbered the procedural steps.

Page 5-3 Added Figure 5-2, Zero Jig Installation.

Page 6-1 Added Overview information. Reformatted the first paragraph under Clear Stack Zero and

Span Calibration into a bulleted list and note regarding the normal levels of day light.

Page 6-1 thru 6-3 Renumbered procedural steps under Clear Stack Zero and Span Calibration.

Page 6-2 Updated Figure 5-2, Zero Calibration to better illustrate PT-1 and PT-3 locations.

Page 6-3 Renumbered procedural steps under Zero Reflector Adjustment.

Page 6-3 Relocated Span Filter Mark procedural steps from the end of the section to follow the Zero

Reflector Adjustment procedural steps.

Page 6-4 Reformatted Record the Zero/Span Values in the Quick Menu into procedural steps.

Reformatted the first paragraph under Off Stack Zero Calibration into a bulleted list and

renumbered the procedural steps.

Page 7-1 Added Overview information.

Page 7-1 thru 7-2 Revised Preventive Maintenance Schedule.

Page 7-4 thru 7-10 Added Corrective Maintenance information along with Figures 7-1 thru 7-6.

Page 8-1 Added Caution.

Page 8-1 thru 8-2 Revised Troubleshooting table to include references.

Page 8-2 Added Air Flow Switch heading and body text.

Page 9-1 Removed information regarding Level III spare parts.

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 1-7 Revised the TTL Bulls-Eye on Figure 1-3, Component Relationships.

Page 1-9 Revised the Product Matrix to read OPM4000 instead of OPM3000.

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

Air Plenum.

HIGHLIGHTS OF CHANGES (CONTINUED)

Effective January, 2007 Rev 1.1 (Continued)

Effective November, 2007 Rev 1.2

Effective October, 2008 Rev 1.3

Page Summary

Page 2-20 Revised the Beam Alignment Procedure. Replaced Figure 2-15, Alignment of the

Transceiver.

Page 4-3 Revised steps 3 and 5 under Alarm Set Point Adjustments, Alarm Time Delay

Adjustments, and Auto Cal Timer Adjustments.

Page 5-3 Revised the logo on the zero jig in Figure 5-2.

Page 6-4 Revised step 3 under Zero Cal Value and Span Cal Value.

Page 9-1 thru 9-2 Revised Section 9, and added three 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.

Page Summary

Page 2-1 Added note regarding installed path length.

Page 2-2 Clarified transceiver distance from stack exit.

Page 2-7 Added note regarding installed path length.

Page 2-15 Added information on recommended transceiver to control room cable.

Page 7-3 Deleted two year maintenance recommendations.

Appendix C Added Appendix C.

Page Summary

Throughout Updated revision level and date.

TOC Updated Table of Contents.

D-1 through D-10 Added Appendix D, OPM 2000 Retrofit Instruction

I-1, I-2 Updated Index of terms.

Back cover Revised e-mail addresses and copywrite date.

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Instruction Manual

IM-105-4000, Rev 1.3

October 2008

TOC-1

OPM 4000

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 4000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Normal Mode of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Internal Calibration System, Zero Mode. . . . . . . . . . . . . . . . . . . . . 1-6

Internal Calibration System, Span Mode . . . . . . . . . . . . . . . . . . . . 1-6

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

System Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Beam Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

SECTION 3

Startup and Calibration

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

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

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

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

Verifying Instrument Operation and Configuration . . . . . . . . . . . . . 3-3

Edit Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Quick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Displaying the Factory Set OPLR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Zero/Span Calibration Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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October 2008

OPM 4000

TOC-2

SECTION 4

Operation

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

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

Front Panel LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Manual Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Alarm Set Point Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Alarm Time Delay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-20 mA Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Recorder or Other Device Calibration . . . . . . . . . . . . . . . . . . . . . . 4-3

Auto Cal Timer Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Remote Calibration Cycle Initiate. . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Remote Calibration Cycle Acknowledgment . . . . . . . . . . . . . . . . . 4-4

Service Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

SECTION 5

Zero Jig and Neutral

Density Filters

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

Zero and Span

Calibration

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

Clear on Stack

Zero and Span Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Zero Reflector Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Span Filter Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Record the Zero/Span Values in the Quick Menu . . . . . . . . . . . . . . . . 6-4

Zero Cal Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Span Cal Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Off Stack Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

SECTION 7

Maintenance

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Control Unit Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Weather cover/blower preventive maintenance. . . . . . . . . . . . . . . . . . 7-3

Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Transceiver Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Service Module Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Circuit Board Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

SECTION 8

Troubleshooting

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Air Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

SECTION 9

Spare Parts

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

TOC-3

OPM 4000

APPENDIX A

Safety Data

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

APPENDIX B

Returning Equipment to

the Factory

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

APPENDIX C

ModBus

Communications

Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

APPENDIX D

OPM 2000 Retrofit

Instructions

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Overview of the Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Removal of Existing Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Remove Transceiver Side Components. . . . . . . . . . . . . . . . . . . . .D-2

Remove Retro Reflector Side Components . . . . . . . . . . . . . . . . . .D-2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Install Retro Reflector Side Components . . . . . . . . . . . . . . . . . . . .D-3

Install Transceiver Side Components. . . . . . . . . . . . . . . . . . . . . . .D-7

Install Stack Service Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Beam Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Startup and Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8

Retrofit Kit

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

TOC-4

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

http://www.raihome.com

OPM 4000 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-105-4000, Rev 1.3

October 2008

OPM 4000

ii

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

components, functions, installation and maintenance of the OPM 4000.

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

N

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

iii

TECHNICAL SUPPORT

HOTLINE:

For assistance with technical problems, please call the Customer Support

Center (CSC). The CSC is staffed 24 hours a day, 7 days a week.

Phone: 1-800-433-6076 1-440-914-1261

In addition to the 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-RSMT (1-800-654-7768)

Emerson Process Management may also be reached via the Internet through

e-mail and the World Wide Web:

e-mail: [email protected]

World Wide Web: www.raihome.com

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

iv

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

http://www.raihome.com

Section 1 Description and Specifications

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

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

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 1-7

COMPONENT

CHECKLIST

A typical Rosemount Analytical OPM 4000 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 4000. Ensure the features and

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

SYSTEM OVERVIEW

General The OPM 4000 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-105-4000, Rev 1.3

October 2008

OPM 4000

1-2

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

38450040

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OPM 4000

Opacity/Dust Density

Monitor

Instruction Manual

IM-105-4000 Rev

. 1.0

May 2006

Model:

Serial:

Operate

Zero

Span

Normal

Test

External

Meter (mA)

Opacity

T

2

0-100%

Model

Serial

1

2

3

4

5

6

7

8

9

10

11

1. Zero Jig

2. Instruction Manual

3. Mounting Plate

4. Control Unit

5. Service Module

6. Air Blower

7. Air Filter

8. Air Hose with Clamps

9. Duplexer

Note: The optional weather

covers are not shown in

the typical system package.

10. Transceiver with

Air Plenum attached

11. Terminal Board

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

1-3

OPM 4000

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

38440041

Model:

Serial:

Notes: 1. Plug air blower into an external AC power source.

2. The optional weather covers are not shown in the

typical system package.

1

2

1. Terminal Board

2. Mounting Plate

3.

4.

5.

6.

Air Blower

Air Filter

Air Hose with Clamps

Retro Reflector with Air Plenum attached

3

4

5

6

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

1-4

Figure 1-2. Transceiver

Assembly with Weather Cover

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.

38450039

Weather

Cover

Mounting

Plate

Duplexer

Terminal

Board

Transceiver

Air Blower

Filter

Service

Module

Control

Unit

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

1-5

OPM 4000

OPM 4000 System

Features

Transmissometer/Retro Reflector

The OPM 4000 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.

Control Unit

Mounted in a control room environment, the OPM 4000 control unit provides

instrument control functions, opacity readings, alarms and fault indicators,

analog outputs, and diagnostics with contact closures.

Service Module

The service module is used to pass signals to and from the transceiver and

control unit, display opacity via digital meter, initiate maintenance zero and

span cycles and insertion of external current meter in the transceiver to

control unit 4-20 mA loop.

Optional Air Purge Weather Cover System

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

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

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

from dirt, moisture, stack temperatures within the specified ambient

temperature limits, and errant air currents around the stack.

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

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

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

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

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

clean for long periods.

Alignment System

The OPM 4000 includes a built-in through-the-lens alignment system. The

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

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

system, which is integral to the air plenum.

Cabling

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

unit is at a minimum 6-pair, #20 AWG, twisted, shielded cable. More pairs or

larger than 20 AWG is acceptable.

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

1-6

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

2

(T

2

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

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

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

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

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

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

lamp. The (T

2

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

Zero Reflector

Span Filter

Span Filter out:

Span Filter in:

Zero Reflector out:

Zero Reflector in:

Transceiver With Auto Zero Span Capability

38450001

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

1-7

OPM 4000

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 up scale reading in accordance

with the latest EPA 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.

SPECIFICATIONS Specifications for the OPM 4000 system are listed in Table 1-1.

Table 1-1. OPM 4000

Specifications

OPM 4000 Specifications

Design and performance Meets or exceeds PS-1 revised and ASTM D6216-98

Peak and Mean Spectral

Response

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

outside 400 to 700 nm

Relative Spectral Response <10%

Angle of View <4.0

o

from optical axis

Angle of Projection <4.0

o

from optical axis

Calibration Error/Accuracy ±1% of full scale

Remote control unit

Numeric Digital Display 5/8 in.

(15,9 mm) 4-digit LED

Selectable for instantaneous opacity, average opacity,

optional mg/m

3

Display Resolution 0.1% Opacity

Alphanumeric 8 character

LED (0.2 in.) Fault Display

Air purge low, No Stack Power, T2 4-20 Lost/low,

Maintenance Mode, Window Dust, Zero Cal Fail, Span Cal

Fail, Manual Cal.

Bargraph Left/Right: 51 segments LED 5.1 in. (129,5 mm) for

instant/average opacity. 20 segment LED 2.1 in. (53,3 mm)

for window dust and drift in % opacity.

Operator Indicating LED’s Run, Alarm, Operate, Cal in progress

High Opacity Set Point 0-100% of full scale

High Opacity Delay Adjustable 0-300 seconds

High Opacity Alarm Reset Automatic

Open Transistor Collector

Outputs

Four selectable

Dry Contacts Two selectable (option: two additional)

Instantaneous Opacity and

Average Outputs

4-20 mA grounded reference, 800 ohms max. (two

additional optional)

OPLR/Exit Correlation

(Lx / 2*Lt)

0.2 to 3.0

Cal Cycle Initiate Local, remote and timed adjustable 1 to 24 hours

Enclosure NEMA 13, IP65, Height: 7.38 in. (187,5 mm) x Width: 3.00

in. (76,2 mm) x Depth: 7.75 in. (196,9 mm), Weight 6 lbs

(2,24 kg)

Ambient Temperature Range 32

o

to 122

o

F (0

o

to 50

o

C)

Ambient Temperature Limits -4

o

to+130

o

F (-20

o

to +54

o

C) (Cold weather option

available.)

Process Gas Up to 750

o

F (400

o

C), standard (higher available-contact

factory)

Power Requirements 120 VAC (±15%), 50/60 Hz, 22VA

Network Protocol: Modbus (ASCII or RTU mode), type RS-485,

optically isolated, RS-232 with telephone modular handset

connector.

Instruction Manual

IM-105-4000, Rev 1.3

October 2008

OPM 4000

1-8

Table 1-2. Product Matrix

OPM 4000 OPACITY DUST DENSITY MONITOR - ORDERING INFORMATION

Select complete model number from the Product Matrix

Configuration Speed: 1200-38,400 baud, type RS-232, and RS-485

Transceiver Service module

Display 5/8 inch (15,9 mm), 4-digit LED, selectable for % opacity

and % transmittance

Local Zero/Span Manual on demand

Test Jacks Transceiver to remote control current loop

Diagnostics Loss of power, current loop open, maintenance mode

Transceiver/Reflector

Enclosure NEMA 4 watertight enclosure

Path Length 3 to 40 feet (0,9 to 12 m) standard, longer available

Optical System Double pass

Light Source Aging

Compensation

Automatic

Light Source Life > 5 years

Alignment Verification Passive built-in through-the-lens system

Mounting Flanges 3 in. IPS, 150 lbs (56 kg) pipe flange

Ambient Light Immunity Solid-state electronic light modulation

Design and Performance

Peak and Mean Spectral

Response

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

outside 400 to 700 nm.

Relative Spectral Response <10%

Angle of View <4.0

o

from optical axis

Angle of Projection <4.0

o

from optical axis

Calibration Error/Accuracy ±1% of full scale

Response Time <10 seconds

Zero Drift <0.5%

Calibration Drift <0.5%

Operational Period In excess of PS-1 required 336 hrs

Zero/Span Calibration Manual or automatic with zero mirror and neutral density

filter

OPM 4000 Specifications

OPM4000 Opacity/Dust Density Monitor

Code Intelligent Electronics

01 Basic Unit – Digital Display, (2) 4-20 mA Outputs, 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’ Path Length

Code Weather Cover and Blowers

00 None

01 Weather Covers and Blowers

02 Weather Covers Only

Code Zero Jig Type

01 Zero Jig and Neutral Density Filters

02 Zero Jig Only

OPM4000 01 12 02 01 Example

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Rosemount OPM 4000 Opacity / Dust Density Monitor-Rev 1.3 Owner's manual

Rosemount OPM 4000 Opacity / Dust Density Monitor-Rev 1.3 Owner's manual

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