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Emerson Rosemount OPM3000, Instruction Manual, Page: 11 / 52

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Emerson Rosemount OPM3000 Instruction Manual Download Page 11

Instruction Manual Rev B 
 

10 

 

 

 

 

 

 

 

 

 

 

Transceiver/ Reflector: 

  

Enclosure 

NEMA 4 watertight enclosure. Power 120/240VAC, 
50/60Hz. +/- 10%, Transceiver 65va, Service Module 
60va. 

Path Length 

3 to 40 feet, 0.6 to 4.6 meters. 

Optical System 

Double Pass 

Reflector 

Distance dependent 

Light Source Aging Compensation 

Automatic 

Light Source Life 

62,000 hours (> 7 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# flange, standard 

Ambient Light Immunity 

Solid-state electronic light modulation 

Wiring 

2 pair twisted shielded cable, 22 AWG 

Summary of Contents for Rosemount OPM3000

Page 1: ...Instruction Manual Rev 2 0 OPM3000 Opacity Dust Density Monitor Installation and Operation Manual Rev 2 0 ...

Page 2: ...Y PROCESS CONSIDERATIONS 12 STACK EXIT CORRELATION COMPUTATIONS 13 Choose an installation site 14 INSTALLATION MECHANICAL 15 Installation procedure stack flanges 15 FLANGE TO STACK INSTALLATION 17 AIR PURGE WEATHER COVER MECHANICAL INSTALLATION 18 MOUNTING THE AIR PLENUM AND WEATHER COVERS 19 Transceiver and retro reflector assembly 20 SECTION 3 CONTROL UNIT RCU OPERATION PAGE DESCRIPTION 21 RCU U...

Page 3: ...IT KIT 35 USING THE ON LINE ZERO REFLECTOR OPTION 35 Procedure 35 Course adjustments 36 FILTER CORRECTION FORMULA 37 Neutral Density Filter certification and standard values 38 SECTION 8 PREVENTIVE CORRECTIVE MAINTENANCE SPARE PARTS 39 Preventive corrective maintenance schedule 39 Trouble Shooting 40 Spare parts 41 SECTION 9 DRAWINGS 42 Electrical wiring OPM6126 43 Mounting stack flanges 38440018 ...

Page 4: ...Instruction Manual Rev B 3 ...

Page 5: ... this equipment Only a technician or engineer trained in the local and national electrical standards should perform tasks associated with the electrical wiring of this device Warnings Under no circumstances will Emerson Process Management be liable or responsible for any consequential damage that may arise as a result of installation or use of this equipment All examples and diagrams shown in the ...

Page 6: ...ry trained service personnel trained in is operation should open the device s housing or carry out repairs The manufacturer is not responsible for problems resulting from improper or irresponsible use of this device You may cause an electric shock fire or damage the equipment if you ignore any of these safety precautions ...

Page 7: ... 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...

Page 8: ...ey 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 a...

Page 9: ... They protect the stack mounted components from dirt moisture stack temperatures within the specified ambient temperatures limits and errant air currents around the stack The air purge system constantly circulates air past the optical window The air flow is directed through the hose to an air plenum on the stack side of the optical window The air flow in the air plenum area results in reduced pres...

Page 10: ...2 to 122o F Power Requirements 24 VDC 10 Flue Gas Stack Duct Pressure 2 51mm Water Column Ma Alarm Time Delay set point 6 Relays for alarms Alarm Reset Manual or Automatic Analog Outputs Two 12 bit Analog outputs 4 20mA Ch 1 0 100 opacity Ch 2 mg m3 selectable ranges Maximum range Opacity 99 9 2 0 O D 2000mg m3 Calibration check options Manual zero and span calibrate with dedicated zero reflector ...

Page 11: ...Pass Reflector Distance dependent Light Source Aging Compensation Automatic Light Source Life 62 000 hours 7 years Ambient Temperature Limits 40 to 130o F 40 to 54o C Process Gas Up to 750o F 400 o C Alignment Verification Built in through the lens system standard Mounting Flanges 3 inch IPS 150 flange standard Ambient Light Immunity Solid state electronic light modulation Wiring 2 pair twisted sh...

Page 12: ... Zero Drift 1 24 hours Calibration Drift 1 24 hours Operational Period 6 Month Severe Weather Cover with dual blowers Material 308 Stainless Steel Quick release pins 2 for bottom and 2 for top release Mounting 3 inch IPS 150 flange Others available Standard Blower Single phase 110 220VAC 50 60Hz Max stack pressure 5 inch WC with the proper installation of purge blowers Wind Speed 60 mph Ambient te...

Page 13: ...e 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 i...

Page 14: ...is 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 c...

Page 15: ... swing clear as shown in the installation drawings Locate the stack mounted units in an area with ambient temperatures between 4 o to 130o F Consult the factory for other temperature ranges Areas that are clean and dry are desirable Avoid areas with condensation Maintenance intervals are directly related to the installation environment Intervals can vary from 2 to 3 months in fairly clean environm...

Page 16: ...quired to supply and install two 3 I P S flanges at eye level directly across from each other The flange faces mounted on pipe stubs should be approximately 6 to 8 from the stack or insulation On completion of the installation the flanges must be aligned so that the total deviation of the light source flange relative to a common centerline does not exceed 1o and the retro reflector flange does not...

Page 17: ...ch the alignment tool to the flange pipe assembly and insert the pipe into the 3 1 2 hole in the stack wall Align the assembly with the 1 2 diameter hole on the opposite side by viewing through the alignment tool and weld the pipe in place Care must be exercised when welding to maintain alignment The 1 2 diameter hole should now be enlarged approximately 3 1 2 to accept the other flange pipe assem...

Page 18: ...Instruction Manual Rev B 17 Flange to stack installation ...

Page 19: ...Instruction Manual Rev B 18 Air purge Weather cover mechanical Installation ...

Page 20: ...he air plenum attached un clip both hold down latches swing open and lift up off the hinge pins Place the Transceiver and retro in a safe place 3 The air plenum is attached to the customer supplied 3 pipe flange by four 2 1 2 long 5 8 11 bolts Working from the 3 flange the correct assembly is gasket then air plenum 4 If you have weather covers remove the two 2 weather cover hood hinge pins located...

Page 21: ...g Caution 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 All wiring from the c...

Page 22: ... on to the previous page The enter or return button is used when entering variable Press it and the variable will change from steady to blinking enter the new value and follow screen tip at the bottom to complete the operation The info button is used for setting the PLC functions This is not used during normal operation When required the use of the functions will be explained in this manual The ke...

Page 23: ...ay Setup or About pages Use the return enter button to enter the page screen you desire To get to the About page scroll down to About and press the right arrow button to enter the 1st page of the about page Press the down arrow to get to the 2nd page Note Press ESC to go back on any page Process Opacity ...

Page 24: ...Choose between 1 auto or 2 manual Auto means when the high opacity alarm has been activated and when the level of smoke drops below the alarm point the alarm contacts 02 04 and icon will reset automatically Manual reset means when the high opacity alarm has been activated pushing the return enter button 04 contact will de energize but 02 will remain energized When the level of smoke drops below th...

Page 25: ...nt from 0 99 with the key pad Esc exit Alarm delay In seconds Use the return enter button to enter the page screen Press the return enter button to set the delay from 0 360 with the key pad Esc exit Early warning setup Press return enter button and set the Early Warning alarm set point to any value below the Alarm set point No delay for Early Warning ...

Page 26: ...struction Manual Rev B 25 Section 4 Modbus Modbus Setup MODBUS I D Press return enter button to enter and key in the node number 1 to 32 desired press Press return enter button to to set then ESC to exit ...

Page 27: ...the register number plus 40 001 To read relay use the coil number Register type Register Name Read register Coil MI 35 Opacity full value 40036 MI 65 OPLR 40066 MB 20 High Alarm 02 04 06 0 off 1 on 20 MB 22 E W Alarm 03 05 0 off 1 on 22 MB 23 Air flow alarm 07 0 off 1 on 23 ...

Page 28: ...e Timeout 0 2 seconds RS485 Pin out Use RS485 to create a multi drop network containing up to 32 devices Note port 1is set to RS485 Note that the ports are not isolated If controller is used with a non isolated external device avoid potential voltage that exceeds 10V To avoid damaging the system all non isolating device ports should relate to the same ground signal Use shielded twisted pair cables...

Page 29: ...ull Scale setup Multiply desired FS by 10 and enter it For example 100 enter 999 for 50 enter 500 Maximum 500 ohm device load Connect the minus wire from your device to the bottom connector terminal 0V and the plus wire from your device to the terminal AO for channel 1 and AI for channel 2 ...

Page 30: ... Manual in the alarm set up page Early warning Relay O3 Set point is chosen in the setup page Group 2 Relays Early warning Relay O5 Set point is chosen in the setup page High opacity Audible alarm Relay O6 may be used for audible alarm and can be reset acknowledged even if the opacity is still above the set point Air purge alarm Relay O7 When the airflow switch is utilized remove the jumper suppli...

Page 31: ...e ranges are set during final test to the information supplied by the customers Field changes can be made in the set up page Maximum output Loop compliance is 500 Ohms OPM3000 Analog output wiring list Bottom Connector Common for mA outputs 0V Positive 4 20mA output CH1 A0 Positive 4 20mA output CH2 A1 ...

Page 32: ... to transceiver and air purge systems 2 Align the Reflector mating flange so it is plumb and parallel to the 3 150 mounting flange Use the 3 adjusting nuts on the air purge plenum flange until this is accomplished The adjusting nuts have nylon locking inserts to prevent loosing by vibration 3 Move to the Transceiver and determine monitor alignment by looking through the viewing port located on the...

Page 33: ...disconnect power when removing or replacing the transceiver cover by removing the screw below the target viewing window and pulling the cover straight back until it clears the Optical plate 1 Connect an accurate meter to measure the 4 20 mA signal from the transceiver to the control unit at terminal 8 9 in the J box Electrical Installation drawing OPM 6126 The meter should be placed in series with...

Page 34: ...the Signal Processor PCB 222 1667 until the mA meter reads the calculated mA of the span filter value using the formula 1 opacity 100 2 x 16 4 mA If no Micro turn is available you can place a black cloth over the transceiver and adjust PT 3 for 4 0ma Repeat adjustments until they are within 04mA Remove the on line reflector and place in a safe place Because the on line reflector was set during ini...

Page 35: ...ove the service module and install the system on portable off stack test stands and at the correct flange to flange distance plus 11 inches The additional 11 inches compensates for air plenum spacing as the air plenums are not used for the off stack zero calibration 2 Clean transceiver and retro windows 3 Connect the control unit with the control to service module test cable kit p n 1469 and apply...

Page 36: ... so as to see the reflector Turn the fine adjustment large knob in a direction which will open the iris to expose more of the reflector This direction will cause the monitor to lower opacity and by turning in the opposite direction closing the iris will raise the opacity 2 Loosen clamps on the transceiver and swing it open and clean the lens use alcohol with a clean lint free paper and leave no fi...

Page 37: ... 5 After the setscrew is tight again try to reach zero repeat if necessary 6 Opacity is above zero and you cannot bring it up after you have turned the adjustment knob as far as it will go into the Micro turn housing perform the following procedure 7 Hold the Micro turn 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 C...

Page 38: ... read differently To calculate what the slide will read with another OPLR use the formula 2 100 100 1 1 1 5 0 2 OP Op M 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 what will it read at OPLR of 1 5 5 54 100 100 1 23 1 1 5 0 5 1 ...

Page 39: ...ed 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 steps and the resulting transmittances of the ...

Page 40: ...Adjust as necessary Air filters 3 months Clean or replace as necessary Air hoses 3 months Replace as necessary Hose clamps 3 months Inspect and tighten Mounting hardware 3 months Check bolts for tightness Weather cover 3 months Clean as required Cables and connectors 6 months Check clean replace as necessary Flange 6 months Push build up into stack to clear flange Clear stack or off stack zero Yea...

Page 41: ... is open Check wiring for open from Terminal 0V I6 on control unit to wire 9 8 at J box location Alignment is good but control unit reads high opacity 1 Reference voltage TP 2 on signal processor 1667 is lower than 9 3V 2 Main lamp out 1 Adjust lamp drive PT 2 on the power modulator 1668 until Reference voltage TP 2 on signal processor 1667 is 10 0 Volts 3v 2 Replace main lamp assembly Control uni...

Page 42: ... 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 CSC you may also contact Field Watch Field Watch coordinates Emerson Process Management s field service throughout the U S and abroad Phone 1 800 654 RMST 1 800 654 7768 Emerson Process Management may also be reached via the Internet through e mail and World Wide Web ...

Page 43: ...Instruction Manual Rev B 42 Section 9 Drawings ...

Page 44: ...Instruction Manual Rev B 43 Electrical wiring OPM6126 ...

Page 45: ...Instruction Manual Rev B 44 Mounting stack flanges 38440018 ...

Page 46: ...Instruction Manual Rev B 45 Sensor mounting with or without weather covers 38440021 ...

Page 47: ...void potential voltage that exceeds 10V To avoid damaging the system all non isolating device ports should relate to the same ground signal Use shielded twisted pair cables Minimize the stub drop length leading from each device to the bus Ideally the main cable should be run in and out of the network device Do not cross positive A and negative B signals Positive terminals must be wired to positive...

Page 48: ...Rev B 47 Purge blower electrical and pressure information Single Phase 110VAC 50 60Hz 220VAC 50 60Hz Run Amps 3 4 1 7 H P 0 25 0 25 0 10 20 30 12 5 17 5 22 5 27 5 37 5 Inch H2O SCFM Standard Blower p n 1A99993H07 Pressure ...

Page 49: ...surement location is in a And is Then use a light beam path that is 1 Straight vertical section of stack or duct Less than 4 equivalent diameters downstream from a bend In the plane defined by the upstream bend see figure 1 1 2 Straight vertical section of stack or duct Less than 4 equivalent diameters upstream from a bend In the plane defined by the downstream bend see figure 1 2 3 Straight verti...

Page 50: ...if 1 the average opacity value measured at the alternative location is within 10 percent of the average opacity value measured at the location meeting the installation criteria and 2 the difference between any two average opacity values is less than 2 percent opacity absolute You use the following procedure to conduct this demonstration simultaneously measure the opacities at the two locations or ...

Page 51: ...Instruction Manual Rev B 50 ...

Page 52: ...Instruction Manual Rev B 51 ...

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