Instruction Manual OPM 3000 Opacity/Dust Density Monitor http://www.raihome.com
HIGHLIGHTS OF CHANGES Page Page 1-6 Page 1-7 Page 2-1 Page 2-5 Page 2-9 Page 2-11 Summary Effective November 12, 2008 Rev 2.0 Revised errant OPRL/Exit Correlation equation to read Lx/2Lt. Revised final Code text to read Dust Density Calculation, 2 places. Revised text of 3rd WARNING from power supply to power source for clarity. Added introductory paragraph to Mechanical Installation topic. Added introductory paragraph to Mounting the Air Plenum topic. Added introductory paragraph to Mounting the Transceiver topic. Page 2-13 Revised major heading to read Wiring Installation. Added introductory paragraph to Wiring Installation. Added Input Connections heading for clarity. Revised instruction sets for remaining three subtopics to better agree with reference wiring diagram, Figure 2-9. Page 2-14 Revised improperly named heading of Figure 2-9 to read Wiring Diagram. Revised content of Figure 2-9 to reflect wiring changes applicable to new controller unit. Added more callouts to wiring diagram for clarity. Page 2-15 Moved previous topic Beam Alignment Procedure to Section 3 to allow completion of all Wiring Installation tasks before commencing beam alignment. Revised Output Connections heading and related subtopic headings to reflect correct task breakdown and clarify contents of Wiring Installation instruction set. Corrected errant terminals nomenclature throughout Output Connections instructions; ie: 02 corrected to read O2. Page 3-1 Moved instruction set of previous Overview topic to follow new Startup heading. Revised and reordered Startup instruction set to reflect a more logical task sequence. Page 3-2 Revised Stack / Exit heading and structure of related equations shown in step 2. Page 3-4 Revised text of first heading and follow on paragraph for clarity. Page 3-5 Revised structure and style of equation shown in step 8. Page 4-1 Revised Overview to reference mg/m3 version procedures in new Appendix A. Corrected perimeters to read parameters throughout section. Revised Main Display Screens heading to read "Selecting a Display Page" to better reflect topic of discussion. Revised instruction set to better agree with view in Figure 4-1. Revised title of Figure 4-1 from Main Page to Opening Page/Screen to avoid confusion with the Main page selected in the display view. (The Main Page will display when the return button is pushed.) Page 4-2 Added About Page heading for clarity. Page 4-4 Added new Figure 4-6, Setup Page for clarity. Added Note to reference additional setup parameters discussion in Appendix A. Page 6-1 Expanded section contents to include component replacement headings. Moved Table 6-1 to page 6-2 to display the full maintenance schedule on a single page. Page 6-2 through 6-6 Revise layout of text and illustration for instructional clarity. Appendix A Added new appendix. Renumbered remaining appendices.
Instruction Manual OPM 3000 Table of Contents Essential Instructions........................................ i Preface................................................. ii Definitions............................................... ii Symbols................................................. ii SECTION 1 Description and Specifications SECTION 2 Installation SECTION 3 Startup and Calibration 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 OPM 3000 - Ordering Information............................ 1-7 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 Wiring Installation....................................... 2-13 Input Connections..................................... 2-13 Output Connections................................... 2-15 RS485 Communications................................ 2-16 Overview............................................... 3-1 Startup................................................. 3-1 Startup Service.......................................... 3-1 Beam Alignment Procedure................................. 3-2 Stack / Exit Correlation.................................... 3-3 Initial Adjustments........................................ 3-4 On Stack Zero and Span Calibration....................... 3-4 http://www.raihome.com
OPM 3000 Instruction Manual SECTION 4 Normal Operation SECTION 5 Zero Jig and Neutral Density Filter SECTION 6 Maintenance SECTION 7 Troubleshooting SECTION 8 Spare Parts APPENDIX A Dust Density Calculation APPENDIX B Safety Data APPENDIX C Returning Equipment to the Factory Overview............................................... 4-1 Control Unit............................................. 4-1 Selecting a Display Page................................ 4-1 About Page........................................... 4-2 Setup of Password Protected parameters................... 4-4 Off Stack Zero Calibration.................................. 4-5 Overview............................................... 5-1 Using the Zero Jig........................................ 5-1 Installation........................................... 5-2 Coarse Adjustments.................................... 5-4 Filter Correction....................................... 5-5 Filter Certification...................................... 5-5 Overview............................................... 6-1 Preventive Maintenance Schedule........................... 6-2 Corrective Maintenance.................................... 6-3 Lamp Replacement.................................... 6-3 Transceiver Fuse Replacement........................... 6-4 Circuit Board Replacement............................... 6-5 Troubleshooting.......................................... 7-1 Spare Parts............................................. 8-1 OPM 3000 Recommended Spare Parts..................... 8-1 Overview............................................... A-1 Correlation with Particulate Density........................... A-1 Calibration.............................................. A-5 Initial Alignment and Calibration........................... A-5 Setup for O.D. Outputs.................................. A-5 Example after the Stack Test............................. A-7 mg/m3 Operation......................................... A-8 Display and Output..................................... A-8 Setup of Password Protected Parameters................... A-9 MODBUS Polling..................................... A-10 Safety Instructions........................................ B-2 Returning Material........................................C-1 TOC-2
Instruction Manual OPM 3000 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. http://www.raihome.com
OPM 3000 Instruction Manual PREFACE DEFINITIONS 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. The following definitions apply to WARNINGS, CAUTIONS and NOTES found throughout this publication. Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not strictly observed, could result in injury, death, or long-term health hazards of personnel. Highlights an 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. NOTE Highlights an essential operating procedure, condition, or statement. SYMBOLS : EARTH (GROUND) TERMINAL : PROTECTIVE CONDUCTOR TERMINAL : RISK OF ELECTRICAL SHOCK : WARNING: REFER TO INSTRUCTION BULLETIN 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. ii
Instruction Manual OPM 3000 Section 1 Description and Specifications Component Checklist............................. page 1-1 System Overview................................ page 1-1 Specifications................................... page 1-6 OPM 3000 - Ordering Information................... page 1-7 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, 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. http://www.raihome.com
ESC May 2006 OPM 3000 Instruction Manual Figure 1-1. Typical System Package (Sheet 1 of 2) 1 OPM 3000 5 6 2 7 3 8 4 9 0 4 Instruction Manual IM-105-3000 Rev. 1.0 OPM 3000 Opacity/Dust Density Monitor 10 2 3 Analytical 9 Model: Serial: 8 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 10. Terminal Board 7 Note: The optional weather covers are not shown in the typical system package. 6 5 38440032 1-2
Instruction Manual OPM 3000 Figure 1-1. Typical System Package (Sheet 2 of 2) 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 2 Model: Serial: 1. Mounting Plate 2. Retro Reflector with Air Plenum attached 38440041 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. 1-3
OPM 3000 Instruction Manual Figure 1-2. Transceiver Assembly with Weather Cover Control Unit Transceiver Duplexer Mounting Plate Filter Weather Cover Air Blower 38440039 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 minimum a 2-pair, #22 AWG, twisted, shielded cable. More pairs or larger than 20 AWG is acceptable. 1-4
Instruction Manual 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-squared (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 TTL Bulls-Eye Projection Lens Retro Reflector Aperture P Main Lamp RD MD Aperture V 38440001 1-5
OPM 3000 Instruction Manual 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 o F (0 to +50 o C) 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 0.2 to 3.0 (Lx / 2Lt) 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 Automatic Compensation Light Source Life 45,000 hours (>5 years) Ambient Temperature Limits -40 to + 130 o F (-40 to +54 o C) Process Gas Up to 750 o F (400 o C) 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 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 1-6
Instruction Manual OPM 3000 OPM 3000 - ORDERING INFORMATION Select complete model number from the Product Matrix, Table 1-2. Table 1-2. 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 Density Calculation 01 None 02 With Dust Density Calculation (mg/m 3 ) OPM3000 01 12 02 00 01 Example 1-7
OPM 3000 Instruction Manual 1-8
Instruction Manual OPM 3000 Section 2 Installation Overview....................................... page 2-1 Installation Considerations........................ page 2-2 Mechanical Installation........................... page 2-5 Wiring Installation................................ page 2-13 Before installing this equipment, read the Safety instructions for the wiring and installation of this apparatus in Appendix B. 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 source is switched off. Failure to do so could cause personal injury or even death. Make sure that the voltage and frequency of the power source match the designations on the analyzer component tags. NOTE If installed path length is not within 10% of the factory set path length, return the unit to the factory so the path length can be reset. OVERVIEW This section describes: Considerations prior to installation. Mechanical installation procedures, including the applicable drawings and pictures to assist in the process. Wiring requirements for the OPM 3000 system. The beam alignment procedure. Output connections for alarms and recording devices. http://www.raihome.com
OPM 3000 Instruction Manual INSTALLATION CONSIDERATIONS Choose an Installation Site Accessibility Clearance Environment Sample Area Stack Exit 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. 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. Installation clearances for the transceiver, retro reflector and optional weather covers are shown in Figure 2-1. Locate the stack-mounted units in an area with ambient temperatures between -40 o to +130 o F (-40 o to 54 o 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 o to 122 o F (0 o to 50 o C). To permit the operator to read and/or change controls, the unit should not be mounted higher than five feet from floor level. 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. The transceiver should be located a minimum of two stack diameters from the stack exit. Ideally the transceiver should be installed eight to ten stack diameters from the stack exit. 2-2
Instruction Manual OPM 3000 Figure 2-1. Installation Clearances and Weather Cover Dimensions 2-3
OPM 3000 Instruction Manual 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 Note: The transceiver and retro reflector are shown with the optional weather covers installed. 38440028 2-4
Instruction Manual OPM 3000 MECHANICAL INSTALLATION Observe the following instructions and guidelines when installing the OPM 3000 transceiver and retro reflector at the stack. NOTE The beam of the instrument must be kept in a horizontal plane; the transceiver cannot be rotated more than ±10 o 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 o and the retro reflector flange does not exceed ±3 o. 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. 2-5
OPM 3000 Instruction Manual NOTE An alignment tool can be purchased from the factory to ensure accurate alignment. 3. Attach the alignment tool to the pipe flange assembly and insert the assembly into the 3-1/2 in. (89 mm) hole in the stack wall. 4. Align the assembly with the 1/2 in. (13 mm) diameter hole on the opposite side by viewing through the alignment tool (Figure 2-3, Stacks Over 6 Feet Across). 5. The flanges must be aligned so that the total deviation of the light source flange relative to a common centerline does not exceed ±1 o and the retro reflector flange does not exceed ±3 o. 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. 6. Weld the pipe flange to the mounting nipple (Figure 2-4). Care must be exercised when welding to maintain alignment. 7. Install the pipe flange assembly 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). NOTE The 1/2 in. (13 mm) diameter hole should now be enlarged to approximately 3-1/2 in. (89 mm) to accept the other flange/pipe assembly. 8. Proceed in the same manner for installation on the opposite side. Install the other pipe flange assembly with the alignment tool attached, and secure to the stack/duct wall (Figure 2-4). Maintain concentric alignment with the pipe flange assembly previously installed on the opposite wall. 2-6
Instruction Manual OPM 3000 Figure 2-3. Mounting the Stack Flanges STACKS UNDER 6 FEET ACROSS 6 in. - 8 in. (152-203 mm) 3 in. Sch 40 Mounting Nipple VERTICAL AXIS 2-1/2 in. (64 mm) Pipe Size to Span as needed (for alignment) GAS FLOW Stack or Breeching Wall OD STACKS OVER 6 FEET ACROSS Alignment Tool ½ in. (13 mm) Alignment Hole 38440018 NOTE If installed path length is not within 10% of the factory set path length, return the unit to the factory so the path length can be reset. 2-7
OPM 3000 Instruction Manual Figure 2-4. Stack Flange Installation 2-8
Instruction Manual OPM 3000 Mounting the Air Plenum and Weather Covers Use the following procedure to mount the air plenum and weather covers. The control unit, transceiver and retro reflector serial numbers must match in order to ensure accurate measurements. After the installation site has been selected and the platform requirements have been met, the mounting flanges should be installed and aligned as described in "Installation of Stack Flanges". Flanges should be installed with the mounting faces on the vertical plane. NOTE Before installing the transceiver, retro reflector, or any type of weather cover, remove the air plenum from both the transceiver and retro reflector. Removal will make the installation easier with less of a chance of damage while attaching the air plenums and optional weather covers. 1. Verify that the control unit, transceiver and retro reflector serial numbers match. 2. If an air plenum is attached to either the transceiver or retro reflector, un-clip the hold-down latch, swing open and lift up and off the hinge pins (Figure 2-6). Place the transceiver and retro reflector in a safe place. 3. If the OPM 3000 is equipped with weather covers, remove the two weather cover hood hinge pins located on the upper right and left hand corner of the hood. NOTE The air plenum and weather cover are attached to the customer supplied 3 in. pipe flange by four 2-1/2 in. long 5/8-11 bolts. 4. Working from the 3 in. pipe flange, assemble in the following order (Figure 2-5): a. gasket b. mounting plate c. gasket d. mating flange and air plenum 5. Place a flat washer onto each of the four 5/8-11 bolts. 6. Once aligned, place the 5/8-11 bolt and flat washer through the top hole of the middle plate so it is flush against the mating flange. 7. Place a split lock washer over the end of the bolt and secure with a nut. Repeat for the remaining three mounting bolts. 2-9
OPM 3000 Instruction Manual Attach Blowers With Dual Blowers Connect an air blower to the air blower port on the transceiver using the air hoses and clamps. Connect the other air blower to the air blower port on the retro reflector using the air hoses and clamps. See Figure 2-5 for the air blower port location. With a Single Blower and Blower Tee Connect the air blower to the blower tee. Using the air hoses and clamps, connect the blower tee to the air blower ports on the transceiver and retro reflector. See Figure 2-5 for the air blower port location. Figure 2-5. Air Plenum Mounting Plate 3 Pipe Flange Mating Flange Middle Plate Mounting Nipple 5/8-11 Bolt (4) Latch Gasket Air Blower Port Gasket Mating Flange and Air Plenum 38440003 2-10
Instruction Manual OPM 3000 Mounting the Transceiver and Retro Reflector Use the following procedure to mount the air transceiver and retro reflector. NOTE The installation procedures below are for both the transceiver and the retro reflector. Installation dimensions and clearances are shown in Figure 2-1. 1. Attach the transceiver and retro reflector to the air plenum assembly by placing them on the hinge pins (Figure 2-6). 2. Close transceiver and retro reflector and secure in place with the two hold-down latches. Figure 2-6. Upper and Lower Hinge Pins Upper Hinge Pin Lower Hinge Pin 38440004 If installed location has a positive pressure the air-purge system must be used continuously during installation to prevent process gases from contaminating optical surfaces or over heating instrument electronics. If the system is shut off for more than momentary interruptions, the instrument may be damaged. Failure to provide continuous air-purge may void the warranty. 3. Power up the air-purge blower to prevent stack particulate from accumulating in the nipple and air-purge housing. Mounting the Control Unit Before you begin: Mount the control unit at eye level for best viewing of the display. Note that the panel itself cannot be more than 0.197 in. (5 mm) thick. Use the following procedures to install the control unit. 1. Make a panel cut-out that measures 3.62 x 3.62 in. (92 x 92 mm). 2. Check the seal on the back of the control unit. The seal must fit snugly against the panel. 3. Slide the control unit into the panel cut-out. 4. Push the two black plastic mounting brackets into the slots on the sides of the control unit as shown in Figure 2-7. 5. Tighten the mounting bracket screws against the panel, as shown in Figure 2-8. 2-11
OPM 3000 Instruction Manual Figure 2-7. Mounting Brackets Mounting Bracket ESC Mounting Bracket OPM 3000 1 2 3 4 5 6 7 8 9 0 38440014 Figure 2-8. Control Unit Installation 0.197 in. max. (5 mm max.) 3.512 in. (89,2 mm) 2.52 in. (64 mm) 0.244 in. (8,2 mm) 38440015 2-12
Instruction Manual OPM 3000 WIRING INSTALLATION Use the following procedure to install the OPM 3000 system wiring. ELECTRICAL SHOCK HAZARD Disconnect and lock out all power before wiring the system. Failure to lock out power may cause serious injury or death. Input Connections The recommended cable connecting the transceiver to the control room unit is Belden PN 8778, six individually shielded twisted pair, 22 AWG, PVC jacketed, 80 o C. Maximum connecting cable length is 1000 feet (305 m) for 22 AWG wire, and 3000 ft (914 m) for 18 AWG wire. Control Unit 1. Refer to the wiring diagram (Figure 2-9). 2. Connect a jumper wire from the +V0 input terminal to the +V0 output terminal of the control unit. 3. Using one lead of a shielded pair, connect input terminal I6 of the control unit to terminal 8 on the weather cover Terminal Board 4. Using the opposite lead of the shielded pair, connect terminal 0V of the control unit to terminal 9 on the weather cover Terminal Board. 5. At the control unit connect the shield wire to the ground connector of the input terminals. 6. At the weather cover connect the shield wire to terminal 7 on the Terminal Board. AC Power Supply and Duplexer 1. Refer to the wiring diagram (Figure 2-9). 2. Using a 600 VAC conductor, connect the line (L) lead from a 115 VAC, 50/60 Hz power source to terminal 1 on the weather cover Terminal Board. 3. Using a 600 VAC conductor, connect the neutral lead wire from the power source to terminal 2 on the weather cover Terminal Board. 4. Connect the ground wire from the power to terminal 3 on the weather cover Terminal Board. 5. The blower is factory wired to the duplexer. Plug the duplexer power cord into a 115 VAC power outlet. DC Power Supply 1. Refer to the wiring diagram (Figure 2-9). 2. Connect a 24 VDC power source (customer supplied) to the 0V and +V output terminals of the control unit. Observe polarity. 2-13
OPM 3000 Instruction Manual Figure 2-9. Wiring Diagram 2-14
Instruction Manual OPM 3000 Output Connections Refer to Figure 2-9. Figure 2-10. Alarm Relay Connection Channel #1, 0-100% Opacity 4-20 ma Output to Recording Devices The maximum device load for the 4-20 ma current loop is 500 ohms. 1. Connect the negative (-) wire from your device to terminal 0V on the bottom connector of the control unit. 2. Connect the positive (+) wire from your device to terminal A0 on the bottom connector of the control unit. Channel #2, 4-20 ma Output to Recording Devices The maximum device load for the 4-20 ma current loop is 500 ohms. Channel #2 is normally programmed for 0-100% opacity, unless your system reads mg/m 3. Then it will be 0-1000 mg/m 3. 1. Connect the negative (-) wire from your device to terminal 0V on the bottom connector of the control unit. 2. Connect the positive (+) wire from your device to terminal A1 on the bottom connector of the control unit. Alarm Output Connections Alarm outputs are driven by a pnp transistor. If you can not use the transistor, connect a 24Vdc relay (max 650 ohm coil) to terminal O2 or O4 on the bottom connector of the control unit as shown in Figure 2-10. The coil will energize when the set limit is exceeded and will de-energize when reset. An additional Alarm 6 may be used for an audible alarm, and can be reset (acknowledged) even if the opacity is still above the set point. For units with the mg/m 3 option, Alarm 7 may be used to signal a loss of purge air flow. To enable the air flow alarm remove the jumper supplied with the controller when an airflow switch is used and connect it to the I2 input per Figure 2-9. When there is sufficient purge air flow the relay remains open. When air flow is low the O7 relay contacts close to signal the alarm and the airflow icon appears on the main display. 2-15
OPM 3000 Instruction Manual Do not apply input voltage to alarm output terminals O2 through O7. Applying an external voltage to one or more of these terminals will damage the equipment. NOTE Make sure the jumper from the +V terminal on the top connector to the +V terminal on the bottom connector is connected. Early Warning Alarm Option Follow "Alarm Output Connections", but connections for early warning alarms are made to the O3 and O5 terminals on the bottom connector of the control unit. RS485 Communications RS485 communications are available at Port 2 via a 6-pin RJ25 connector. RS485 cabling may be up to 2000 ft. (610 m) in length. Belden P/N 3106A cable is recommended. NOTE The RS485 communication parameters can not be changed in the field; the controller must be returned to the factory. If RS485 Communications settings are not specified in the original order, the factory default settings are as follows: Baud Rate 9600 Data Bits 8 Parity None Flow Ctrl None Timeout 0.2 seconds 2-16
Instruction Manual OPM 3000 Section 3 Startup and Calibration Overview....................................... page 3-1 Startup......................................... page 3-1 Startup Service.................................. page 3-1 Beam Alignment Procedure........................ page 3-2 Stack / Exit Correlation............................ page 3-3 Initial Adjustments............................... page 3-4 OVERVIEW This section covers the OPM 3000 equipment startup procedure and the adjustments and alignments required prior to initial operation of the system. Read the entire manual to familiarize yourself with the instrument before attempting these alignment and calibration procedures. STARTUP You must complete the following startup tasks before commencing OPM 3000 monitor operations. 1. Measure and record flange-to-flange distance for use in future off-line calibration procedures. 2. The air purge and weather cover system, transceiver, and retro reflector must be installed and power applied. 3. All OPM 3000 wiring and mechanical installations must be completed. All wiring must be checked. NOTE If you are planning to use a recorder, DAS, etc., DO NOT CONNECT THEM NOW. Outputs and inputs from other sources should be left off until system has been completely checked according to the instructions in this section. You should connect and test the customer s external equipment after the proper function and operation of the OPM 3000 system has been verified. 4. To start up the OPM 3000 apply 115 VAC and 24 VDC power to the control unit. Observe the control unit display for indications of proper equipment operation. Refer to Section 4: Normal Operation. 5. Connect the control unit to the customer s equipment as applicable. STARTUP SERVICE Emerson Process Management is available to assist you; call our Customer Support Center (CSC) at 1-800-433-6076 for details and to schedule startup. http://www.raihome.com
OPM 3000 Instruction Manual BEAM ALIGNMENT PROCEDURE Use the following procedure to align the beam. NOTE The control unit does not have to be connected or powered to perform an alignment. For alignment accuracy the stack should be at normal temperature. NOTE Beam alignment should be completed before instrument calibration. 1. Apply power to all air purge systems. 2. Adjust the 3 adjusting bolts on the middle plate (Figure 3-1) so it is parallel to the mating flange. The adjusting bolts have nylon locking inserts to prevent loosening by vibration. 3. Look through the viewing port located on the rear of the transceiver to determine monitor alignment. 4. Adjust the 3 adjusting bolts to align the beam image in the center of the cross hair (bulls-eye) as shown in Figure 3-1. Figure 3-1. Alignment of the Transceiver. Adjusting Bolts Beam image in the center of the cross hair 38440044 3-2
Instruction Manual OPM 3000 STACK / EXIT CORRELATION NOTE The stack exit correlation is especially important to verify. If possible, all dimensions should be verified by actual measurements. 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 (Figure 3-2). If the ratio is greater than 1.0, the exit opacity will be greater than the opacity at the instrument location. The OPM 3000 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 Factory OPLR are within ±2%. Example: A stack with a 120 in. (3048 mm) stack exit ID and a 120 in. (3048 mm) pathlength. 3. Enter the exit diameter (Lx) and measured diameter (Lt) in the control unit. Refer to Section 4: Normal Operation, for information on using the control unit. Figure 3-2. Lx and Lt Stack Dimensions Lx Stack TRANSCEIVER RETRO REFLECTOR Lt Lf Note: Transceiver and retro reflector are shown without the optional weather covers. 38440027 3-3
OPM 3000 Instruction Manual INITIAL ADJUSTMENTS On Stack Zero and Span Calibration The following equipment adjustments must be made prior to operation of the OPM 3000. NOTE The instrument has been calibrated at the factory to specifications received from the customer. When the flange to flange dimensions are exactly as cited, the initial adjustments required are minimal. NOTE For detailed information on using the zero jig, refer to Section 5: Zero Jig and Neutral Density Filter. Before adjusting the OPM 3000 verify the following conditions: The boiler or process is shut down and a clear stack condition exists (if not, use the optional OPM 3000 test flange kit.) Power is disconnected whenever removing or replacing the transceiver housing. The transceiver and retro reflector lenses are clean. The beam alignment procedure has been completed. Use the following steps to perform the zero and span calibrations. Proceed only with a clear stack condition. 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back until it clears the optical plate. 2. Connect a multimeter to measure the 4-20 ma signal from the transceiver to the control unit. Use terminals 8 (+) and 9 (-) on the transceiver terminal board (TB) (Figure 2-9). Connect the multimeter in series with the signal wiring or remove both signal wires and place the mutimeter across terminals 8 (+) and 9 (-). NOTE Allow opacity readings to stabilize before proceeding to the next step. Wait one minute for maximum accuracy. 3. Adjust PT-1 (zero) (Figure 3-3) on the R/M signal processor board slowly clockwise several turns until the 4-20 ma signal decreases to 10 ma. 4. Slowly turn the PT-1 (zero) counterclockwise until the 4-20 ma signal increases to 20 ma (zero % opacity). 3-4
Instruction Manual OPM 3000 Figure 3-3. Zero and Span Adjustments PT-1 (Zero) PT-3 (Span) 38440031 NOTE If attempting an alignment without the optional zero jig please call our Customer Support Center at 1-800-433-6076. 5. Swing open the transceiver and attach the zero jig by placing it on the alignment pins and secure it to the transceiver with the thumb screw. 6. Adjust the zero jig with the large knurled adjustment knob until the 4-20 ma output reads 20 ma, this simulates a zero % opacity condition. Lock the knurled adjustment knob in place. 7. Place a span filter of at least 80% in the slot provided in the zero jig. 8. Adjust PT-3 (span) on the R/M signal processor board until the 4-20 ma output reads the value calculated using the equation: The 4-20 ma output must match the calculated value within ±0.04 ma. 9. Remove the zero jig and store in a safe place. If at any time you need to check the clearance across stack zero, install the zero jig. Because the zero jig was set during initial calibration it can be used to re-establish the across stack zero even if the source is running. 10. Initial calibration of the unit is complete. Reconnect any wires disconnected during this procedure and replace the cover. Clamp the cover securely in place. 3-5
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Instruction Manual OPM 3000 Section 4 Normal Operation Overview....................................... page 4-1 Control Unit..................................... page 4-1 Off Stack Zero Calibration......................... page 4-5 OVERVIEW This section describes: Operation of the OPM 3000 through the control unit. How to edit the password parameters. The operating procedures in this section apply to the OPM 3000 when used for setup and calibration of the instrument for opacity measurements. When the OPM 3000 is used for dust density measurement and is configured with the mg/m 3 option, refer to Appendix A: Dust Density Calculation for instrument setup, calibration, and selective operating procedures. CONTROL UNIT Selecting a Display Page See Figure 4-1. When power is first applied to the control unit the control cursor points to Main; the Main page is selected. 1. To access the Main page/screen press the enter button ( ). 2. To select the Setup or About pages, push the up button (#1 ) or the down button (#6 ) until the cursor points to the desired page/screen. 3. Use the enter button ( ) to access the selected page/screen. Figure 4-1. Opening Display Page/Screen http://www.raihome.com
OPM 3000 Instruction Manual About Page To access the About page: 1. Scroll up using button (#1 ) or down using button (#6 ) to select About (Figure 4-2). Figure 4-2. About Page 2. Press the enter button ( ) to access the first page (Figure 4-3) of the About display screens. The Model, Date Mfd and Stack exit ID are displayed. 3. To toggle between the next and previous screens, press the left and right arrow keys. These keys are located to the left of the display screen. Figure 4-3. First About Page 4-2
Instruction Manual OPM 3000 4. Press the button to toggle to the second About display screen (Figure 4-4). This page contains the Sensor loc ID, Flange to flange measurement and the OPLR (Optical Path Length Ratio). Figure 4-4. Second About Page 5. To display the process opacity, press ESC until the home screen is displayed (Figure 4-1). 6. With the arrow pointing to Main press the enter ( ) button to display the process opacity shown in Figure 4-5. Figure 4-5. Process Opacity 4-3
OPM 3000 Instruction Manual Setup of Password Protected parameters 1. From any screen press ESC until the Main, Setup and About home screen is visible. 2. Scroll down to Setup using the (#6 ) button. 3. Press the enter ( ) button and type in the password 1234. The opening Setup page (Figure 4-6) is displayed. Figure 4-6. Setup Page 4. Choose one of the 6 parameters you want to set or change: a. Exit diameter (Exit dia). b. Measurement diameter (Measurement dia). Exit and Measurement diameters must be in the same scale (i.e., inches, feet, mm, cm, etc.). These measurements are used to automatically change the OPLR and will be displayed in the 2 nd About page. c. Auto/Manual reset - In Auto Reset the alarm is cleared when the opacity level drops below the alarm set points. In Manual Reset alarms are latched until the enter ( ) button is pressed. d. Alarm set point - 0-99%. Must be above Early Warning set point. e. Alarm delay - In seconds. f. Early warning set point - 0-99%. Must be below Alarm set point. NOTE Additional setup parameters are available for units with the dust density (mg/m 3 ) option. Refer to Appendix A: Dust Density Calculation for details. 4-4
Instruction Manual OPM 3000 OFF STACK ZERO CALIBRATION This procedure may be used if: A clear stack condition is not possible, and the zero appears to be incorrect. The flange to flange distance on site is different than the original factory set up. 1. Remove the transceiver and retro reflector from the hinge pins. 2. Install the system on test stands at the correct flange to flange distance plus 11 in. (279 mm). The additional 11 in. (279 mm) compensates for air plenum spacing, as the air plenums are not used for the off stack zero calibration. If test stands are not available an alternate method is to use 3 in. pipe flanges with air plenums installed. Contact the factory for air plenum availability. Set the spacing between the 3 in. pipe flanges exactly the same as the flange-to-flange measurement. 3. Clean transceiver and retro reflector windows. 4. The retro reflector must be level. 5. Follow the instructions for "On Stack Zero and Span Calibration" in Section 3: Startup and Calibration. 4-5
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Instruction Manual OPM 3000 Section 5 Zero Jig and Neutral Density Filter Overview....................................... page 5-1 Using the Zero Jig............................... page 5-1 OVERVIEW USING THE ZERO JIG This section describes: The purpose and functions of the zero jig. Installation procedures for the zero jig. How to calculate the filter values using the OPLR. How to make adjustments on the iris. The zero jig (Figure 5-1), or Micro-turn 200, on-line test and audit system contains a test reflector, an 84% neutral density filter, filter certification certificates and a carrying case. The zero jig on-line test and audit system may be used for: Opacity audit Linearity checks and adjustments System accuracy verification Service on-line or off-stack Figure 5-1. Zero Jig Mounting Screw Fine Adjustment (Large Knob) Reflector Plate 38440042 http://www.raihome.com
OPM 3000 Instruction Manual Installation The zero jig (Figure 5-1) on-line test reflector is inserted over the transceiver lens. The filters provided are marked in single-pass opacity; this is the same as double-pass with a correlation factor (OPLR) of 0.50. 1. Hold the zero jig in a position to see the reflector. Turn the fine adjustment (large knob) so the iris begins to open, exposing more of the reflector. This direction will cause the monitor to lower opacity. To raise opacity, turn in the opposite direction so the iris begins to close. 2. Loosen clamps on the transceiver and swing it open. 3. Clean the lens using alcohol and a clean lint free paper that will leave no film on the lens. 4. Place the zero jig on the two alignment pins (Figure 5-2) with the reflector facing toward the transceiver (away from the stack). 5. Secure the device to the transceiver by tightening the mounting screw. 6. Using the fine adjustment (large knob) start by raising the opacity level above zero then slowly turn the knob in the opposite direction to just reach zero. If you cannot reach zero, or you cannot come above zero, see "Coarse Adjustments". 7. Place the neutral density slides in the slot provided on the top of the device just behind the mounting screw. The system should read the same value written on the label within ±2%. 5-2
Instruction Manual OPM 3000 Figure 5-2. Zero Jig Installation Mounting Screw Alignment Pin Alignment Pin Iris Note: The zero arm, located below the iris on the transceiver, is not included with the OPM 3000. Fine Adjustment (Large Knob) 38440043 5-3
OPM 3000 Instruction Manual Coarse Adjustments Opacity Below Zero If the opacity reading is below zero and you can not reach zero after you have turned the adjustment knob as far as it will go into the zero jig housing, perform the following procedure: Do not force the knob. Stop at the first sign of binding. 1. Hold the zero jig in your hand so you can see the iris and retro reflector. Turn the fine adjustment knob so that the iris is closed as far as it will go. 2. Loosen the coarse adjustment set screw. 3. Turn the fine adjustment knob in the opposite direction as far as it will go. 4. Tighten the coarse adjustment set screw. Be sure not to tighten more than 1/16 of a turn to prevent damage to the iris ring. 5. After the setscrew is tight again try to reach zero. Repeat if necessary. Opacity Above Zero If the opacity reading is above zero and you can not bring it up after you have turned the adjustment knob as far as it will go into the zero jig housing, perform the following procedure: Do not force the knob. Stop at the first sign of binding. 1. Hold the zero jig in your hand so you can see the iris and retro reflector. Turn the adjustment knob so that the iris is open as far as it will go. 2. Loosen the coarse adjustment set screw. 3. Turn the fine adjustment knob in the opposite direction as far as it will go. 4. Tighten the coarse adjustment set screw. Be sure not to tighten more than 1/16 of a turn to prevent damage to the iris ring. 5. After the setscrew is tight again try to reach zero. Repeat if necessary. 6. After performing all of the above steps, if you can not reach zero, or zero is unstable, contact the factory for assistance. 5-4
Instruction Manual OPM 3000 Filter Correction If you have an OPLR (correlation factor) other than 0.5, your neutral density slides will read differently. To calculate what the slide will read with another OPLR use the following equation: Where: OP1 = Standard filter value in % M2 = OPLR for your instrument OP2 = Standard filter value at your OPLR in % Example: Standard filter value is 23.1%. Find what it will read at OPLR of 1.5. Filter re-calibration is available from Emerson Process Management. If not regulated by EPA regulations in your state to a more frequent schedule, we suggest you re-calibrate once a year, at a minimum. If you have filters from other manufacturers we can calibrate them as well (call for pricing). Filters are tested per USA Code of Federal Regulations 40CFR60 Appx. B, Performance Specification 1, Section 7.1.3 Attenuation Calibration. Filter Certification QA/QC testing by Emerson Process Management of the filters at an interval of not more than 6 months is recommended. Filter certification, replacement, or additional neutral density filters are available from Emerson Process Management. Emerson s Rosemount Analytical neutral density filters for the zero jig are calibrated on a Perkin-Elmer Lambda Series 6 / PECSS Spectrophotometer per Federal Environmental Protection Agency specifications. These specifications are contained in the Code of Federal Regulations 40 CFR 60, Appendix B, Performance Specification 1, Attenuator Calibration. The filters are scanned over the visible region from 380 to 780 nanometers in one nanometer step and the resulting transmittances of the filter are weighted to the Source C Human Eye Response by multiplying each value by its associated response factor. The corrected values of transmittance are converted to % opacity and the value is recorded on the filter and associated chart. 5-5
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Instruction Manual OPM 3000 Section 6 Maintenance Overview....................................... page 6-1 Preventive Maintenance Schedule.................. page 6-2 Corrective Maintenance........................... page 6-3 Lamp Replacement............................... page 6-3 Transceiver Fuse Replacement..................... page 6-4 Circuit Board Replacement........................ page 6-5 Install all protective equipment covers and safety ground leads after equipment repair or service. Failure to install covers and ground leads could result in serious injury or death. OVERVIEW This section describes the routine maintenance of the Rosemount Analytical OPM 3000 Opacity/Dust Density Monitor. The amount of maintenance required depends on the environment to which the instrument is subjected. A unit that is subjected to extremely dusty conditions, vibration, and movement will require considerably more maintenance than a unit that is rigidly mounted in a clean, dust-free atmosphere. http://www.raihome.com
OPM 3000 Instruction Manual PREVENTIVE MAINTENANCE SCHEDULE Item to Check Frequency Procedure Zero/Span Daily Check that readings are within specification (±2%), refer to Section 3: Startup and Calibration. Beam alignment Monthly or as required Clean and adjust as necessary, refer to "Output Connections" in Section 2: Installation. Projection lens Monthly or as required Clean with optical cloth and lens cleaning fluid. Transceiver and retro reflector windows Zero reflector Monthly or as required Monthly or as required Clean with optical cloth and lens cleaning fluid. Clean with optical cloth and lens cleaning fluid. Refer to Section 5: Zero Jig and Neutral Density Filter, for additional help. Air blower 3 months Check for excessive noise. Air filters 3 months Clean or replace as necessary. Air hoses 3 months Replace as necessary. Hose clamps 3 months Inspect and tighten. Electrical connections 3 months Make sure electrical connections are wired correctly and secure. Refer to "Wiring Installation" in Section 2: Installation. Mounting hardware 3 months Check bolts for tightness. Weather cover 3 months Clean as required. To access or remove, refer to "Mounting the Air Plenum and Weather Covers" in Section 2: Installation. Weather cover gaskets 3 months Check for leakage. To access, refer to "Mounting the Air Plenum and Weather Covers" in Section 2: Installation. Cables and connectors 6 months Check, clean, replace as required. Flange 6 months Push build-up into stack to clear flange. To access refer to "Installation of Stack Flanges" in Section 2: Installation. Air plenum Yearly Remove transceiver and retro reflector to clean air plenum. Refer to "Mounting the Air Plenum and Weather Covers" in Section 2: Installation. Clear stack zero Yearly To calibrate refer to "On Stack Zero and Span Calibration" in Section 3: Startup and Calibration. System operations Yearly Check all system operations. Refer to Section 4: Normal Operation. Transceiver and retro reflector 3-5 years (site dependent) Return to the factory for internal alignment and cleaning. To access or remove, refer to Section 2: Mounting the Transceiver and Retro Reflector in Section 2: Installation. Additional Preventive Maintenance Yearly Corrective and preventive maintenance schedules should be adjusted according to site specific conditions to ensure the maximum availability of accurate measurement data. Routine checks should be implemented to: Observe and correct the operation of the air-purge system giving particular attention to keeping the optical path within the mounting flanges clear of dirt build-up. Observe and correct the operation of peripheral accessory equipment such as recorders, computers, etc. Observe and correct the stack zero measurement whenever a clear stack condition exists. Care should be exercised to ensure that both transmittance and opacity measurements are at their prescribed values. Verify that instrument operating manuals are available and that maintenance logs are properly maintained and reviewed. Replace any worn hoses and gaskets. 6-2
Instruction Manual OPM 3000 CORRECTIVE MAINTENANCE Disconnect all power before installing or replacing components. Failure to disconnect power may result in electrical shock and/or damage to the equipment. NOTE Make sure to carefully record the wiring connections and locations before disconnecting. This will aid in the installation of the unit. Lamp Replacement 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back until it clears the optical plate. 2. Remove the lamp wire connector from the J2 socket on the R/M signal processor board. 3. Remove the two socket head cap screws (Figure 6-1) using an Allen wrench. Remove the lamp holding fixture. 4. Turn the set screws to loosen the clamp for lamp removal. 5. Remove the lamp assembly consisting of the lamp, wires and connector. 6. Install new lamp assembly in the lamp holding fixture and tighten set screws. 7. Install lamp holding fixture and secure with the two socket head cap screws. Connect J2. 8. Calibrate the OPM 3000 per Section 3: Startup and Calibration. 9. Install cover. Figure 6-1. Lamp/Bulb Removal 6-3
OPM 3000 Instruction Manual Transceiver Fuse Replacement 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back until it clears the optical plate. 2. Pull fuse (F1) from the clamp (Figure 6-2). 3. Firmly press new fuse into the clamp on the power/modulator board. 4. Install cover. Figure 6-2. Transceiver Fuse Transceiver Fuse (F1) 38440034 6-4
Instruction Manual OPM 3000 Circuit Board Replacement The R/M signal processor board and the power/modulator board are located directly across from each other inside the transceiver housing (Figure 6-3). R/M Signal Processor Board Replacement 1. Remove the transceiver cover by removing the screw below the target viewing window and pulling the housing straight back until it clears the optical plate. 2. Tag and remove all wiring connected to the signal processor board. 3. Remove the four nuts (Figure 6-3) from the screw posts holding the signal processor board in place. 4. Install new signal processor board. Install wiring removed in step 2. 5. Calibrate the OPM 3000 per Section 3: Startup and Calibration. 6. Install cover. Figure 6-3. Circuit Board Locations R/M Signal Processor Board Nut Nut Power/Modulator Board Nut 38440031 6-5