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Instruction ManualIB-106-2001 Original IssueJuly 2001

http://www.processanalytic.com

Model OPM 2001Transmissometer Opacity/DustDensity Transmitter

Emerson Process ManagementRosemount Analytical Inc.Process Analytic Division1201 N. Main St.Orrville, OH 44667-0901T (330) 682-9010F (330) 684-4434e-mail: [email protected]://www.processanalytic.com

ESSENTIAL INSTRUCTIONSREAD THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national andinternational standards. Because these instruments are sophisticated technical products, youMUST properly install, use, and maintain them to ensure they continue to operate within theirnormal specifications. The following instructions MUST be adhered to and integrated into yoursafety program when installing, using, and maintaining Rosemount Analytical products. Failure tofollow 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 Rosemount Analytical repre-sentative 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 mainte-nance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate In-struction Manual and per applicable local and national codes. Connect all products to theproper 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 partsspecified by Rosemount. Unauthorized parts and procedures can affect the products per-formance, 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, exceptwhen maintenance is being performed by qualified persons, to prevent electrical shockand personal injury.

The information contained in this document is subject to change without notice.

Instruction ManualIB-106-2001 Original Issue

July 2001

Rosemount Analytical Inc. A Division of Emerson Process Management i

Model OPM 2001

TABLE OF CONTENTS

PREFACE........................................................................................................................P-1Definitions ........................................................................................................................ P-1Safety Instructions .......................................................................................................... P-2Glossary of Terms ......................................................................................................... P-3

1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-11-1 Component Checklist of Typical System (Package Contents).................................. 1-11-2 System Overview............................................................................................................ 1-11-3 Method of Measurement................................................................................................ 1-61-4 Specifications................................................................................................................... 1-71-5 System Startup Procedure ............................................................................................ 1-9

2-0 INSTALLATION .............................................................................................................. 2-12-1 General ............................................................................................................................ 2-12-2 Choosing a Location...................................................................................................... 2-12-3 Calibration........................................................................................................................ 2-22-4 Mounting Flanges to Stack ........................................................................................... 2-22-5 Lifting and Handling....................................................................................................... 2-32-6 Mounting Instructions ..................................................................................................... 2-42-7 Monitoring Opacity in High Temperature Applications ............................................... 2-72-8 Monitoring Opacity at Low Ambient Temperatures ................................................... 2-92-9 System Wiring Installation ............................................................................................. 2-9

3-0 OPERATION ................................................................................................................... 3-13-1 Overview.......................................................................................................................... 3-13-2 HART Communicator Signal Line Connections .......................................................... 3-13-3 Offline and Online Operations ...................................................................................... 3-43-4 HART Operator Interface Description ......................................................................... 3-43-5 Using the HART Interface............................................................................................. 3-63-6 PROCESS VARIABLES Menu...................................................................................... 3-73-7 DIAG/SERVICE Menu .................................................................................................. 3-103-8 BASIC SETUP Menu................................................................................................... 3-193-9 DETAILED SETUP Menu .............................................................................................. 3-223-10 REVIEW Menu.............................................................................................................. 3-293-11 HART Communicator Menu Tree for OPM 2001 ................................................... 3-29

4-0 ALIGNMENT ................................................................................................................... 4-14-1 Optical Alignment ........................................................................................................... 4-14-2 Objective Lens Adjustment............................................................................................ 4-4

5-0 TRANSCEIVER AND RETROREFLECTOR MODULES ............................................ 5-15-1 Transceiver Module ........................................................................................................ 5-15-2 Retroreflector Module ..................................................................................................... 5-85-3 Purge Air Failure Flow Switch ..................................................................................... 5-95-4 Air Lens Assembly....................................................................................................... 5-10


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6-0 INTELLIGENT ELECTRONICS ..................................................................................... 6-16-1 General ............................................................................................................................ 6-16-2 Intelligent Electronics (General Purpose)..................................................................... 6-16-3 Type 4x Intelligent Electronics (Option)...................................................................... 6-5

7-0 MAINTENANCE AND SERVICE .................................................................................. 7-17-1 General ............................................................................................................................ 7-17-2 Preventative Maintenance .............................................................................................. 7-17-3 Repair .............................................................................................................................. 7-37-4 Zero Jig........................................................................................................................... 7-97-5 Fuse Replacement ....................................................................................................... 7-10

8-0 TROUBLESHOOTING.................................................................................................... 8-18-1 General ............................................................................................................................ 8-18-2 System Mode Indicators ................................................................................................ 8-18-3 Diagnostics ...................................................................................................................... 8-18-4 Test Procedures ............................................................................................................. 8-6

9-0 RETURN OF MATERIAL .............................................................................................. 9-1

10-0 REPLACEMENT PARTS ............................................................................................. 10-1

11-0 APPENDICES ............................................................................................................... 11-1Appendix A ................................................................................................................... 11-1Appendix B ................................................................................................................. 11-11Appendix C ................................................................................................................. 11-13

12-0 INDEX............................................................................................................................ 12-1

13-0 DRAWINGS AND SCHEMATICS............................................................................... 13-1


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Rosemount Analytical Inc. A Division of Emerson Process Management iii

Model OPM 2001

LIST OF ILLUSTRATIONS

Figure 1-1. Standard Model OPM 2001 TransmissometerOpacity/Dust Density Transmitter .......................................................................... 1-2

Figure 1-2. Component Relationships...................................................................................... 1-3Figure 1-3. Calibration Dimensions.......................................................................................... 1-4Figure 1-4. Relationship of Opacity, Transmittance, and Optical Density................................ 1-4Figure 1-5. Example Relationship of Extinction and Dust Concentration ................................ 1-5Figure 2-1. Transmitter Location Considerations..................................................................... 2-1Figure 2-2. Transmitter Location .............................................................................................. 2-2Figure 2-3. Stack Flange Installation........................................................................................ 2-3Figure 2-4. Lifting and Handling ............................................................................................... 2-4Figure 2-5. Stack Installation Dimensions................................................................................ 2-5Figure 2-6. Intelligent Electronics Mounting Dimensions ......................................................... 2-6Figure 2-7. Insulation and Cooling Fin Installation................................................................... 2-8Figure 2-8. Optional Purge Air Heater.................................................................................... 2-10Figure 2-9. Customer Connections for OPM 2001

with General Purpose Intelligent Electronics (Sheet 1 of 2) ................................ 2-12Figure 2-9. Customer Connections for OPM 2001

with General Purpose Intelligent Electronics (Sheet 2 of 2) ................................ 2-13Figure 2-10. Customer Connections for OPM 2001

with Optional Type 4X Intelligent Electronics (Sheet 1 of 2) ............................... 2-14Figure 2-10. Customer Connections for OPM 2001

with Optional Type 4X Intelligent Electronics (Sheet 2 of 2) ............................... 2-15Figure 2-11. General Purpose Intelligent Electronics Relay

and Analog Output Connections.......................................................................... 2-16Figure 3-1. HART Terminal Connections ................................................................................. 3-2Figure 3-2. Signal Line Connections, ≥250 Ohms Lead Resistance ....................................... 3-3Figure 3-3. Signal Line Connections, <250 Ohms Lead Resistance ....................................... 3-4Figure 3-4. HART Communicator Operator Interface .............................................................. 3-4Figure 3-5. On-line Menu ......................................................................................................... 3-6Figure 3-6. LCW Locations....................................................................................................... 3-8Figure 3-7. Zero Jig and EPA Filter Placement...................................................................... 3-16Figure 3-8. lx and lt Stack Dimensions................................................................................... 3-21Figure 3-9. Sectored LCW2 ................................................................................................... 3-23Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 1 of 3) ............................................ 3-30Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 2 of 3) ............................................ 3-31Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 3 of 3) ............................................ 3-32Figure 4-1. Optical Alignment................................................................................................... 4-2Figure 4-2. View of Crosshairs and Tolerance Areas in Optical Alignment Sight.................... 4-3Figure 4-3. Objective Lens Adjustment .................................................................................... 4-5Figure 5-1. Transceiver Module - Exploded View .................................................................... 5-0Figure 5-2. Transceiver Optical Assembly - Exploded View .................................................... 5-2Figure 5-3. Stack Light Path..................................................................................................... 5-3Figure 5-4. Ambient Light Path................................................................................................. 5-4Figure 5-5. Dark Mode ............................................................................................................. 5-4Figure 5-6. Lamp Light Path..................................................................................................... 5-5Figure 5-7. Zero Jig Mounting Location ................................................................................... 5-5Figure 5-8. Effective Spectral Response Curve....................................................................... 5-6Figure 5-9. Optical Mounting Channel (with Boards) .............................................................. 5-6Figure 5-10. Detector Circuit ...................................................................................................... 5-7Figure 5-11. Stack LON Board ................................................................................................... 5-7


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Figure 5-12. Retroreflector and Air Lens Assembly ................................................................... 5-8Figure 5-13. Air Lens Assembly and Purge Air Failure Flow Switch.......................................... 5-9Figure 5-14. Air Lens Assembly - Exploded View.................................................................... 5-10Figure 6-1. General Purpose Intelligent Electronics - Exploded View ..................................... 6-1Figure 6-2. IG-1 Software Board .............................................................................................. 6-2Figure 6-3. HART Daughter Board........................................................................................... 6-3Figure 6-4. HART Daughter Board Relay Contact Configurations........................................... 6-5Figure 6-5. Type 4X Intelligent Electronics - Exploded View ................................................... 6-6Figure 6-6. Termination Board ................................................................................................. 6-7Figure 6-7. Power Supply......................................................................................................... 6-7Figure 7-1. External Filters - Exploded View............................................................................ 7-2Figure 7-2. Internal Filter - Exploded View............................................................................... 7-3Figure 7-3. Lamp Replacement................................................................................................ 7-4Figure 7-4. Detector/Amplifier Board........................................................................................ 7-5Figure 7-5. Beam Splitter Adjustment and LCW Replacement................................................ 7-6Figure 7-6. VLAMP Adjustment ................................................................................................... 7-7Figure 7-7. Zero Jig Adjustment and Locking Screws ............................................................ 7-9Figure 8-1. PS1 and PS2 Test Points ...................................................................................... 8-6

LIST OF TABLES

Table 3-1. Function Keys ........................................................................................................ 3-5Table 3-2. Action Keys ............................................................................................................ 3-6Table 3-3. System Status Modes............................................................................................ 3-7Table 3-4. FLD DEVICE VOLTS Submenu ............................................................................ 3-8Table 3-5. LCW States............................................................................................................ 3-8Table 3-6. OUTPUT VARIABLES Submenu........................................................................... 3-9Table 3-7. REF. VOLTAGES Submenu................................................................................ 3-13Table 3-8. FLTR CHK Submenu........................................................................................... 3-15Table 3-9. SETUP CLOCK Submenu ................................................................................... 3-19Table 3-10. PV, SV, and TV RANGE VALUES Submenu ...................................................... 3-20Table 3-11. DEVICE INFO Submenu. .................................................................................... 3-21Table 3-12. RELAY CONFIG Submenu.................................................................................. 3-22Table 3-13. ZERO/SPAN CHECK Submenu.......................................................................... 3-24Table 3-14. LCW Sector Status .............................................................................................. 3-25Table 3-15. AVERAGES Submenu......................................................................................... 3-26Table 3-16. ALARMS Submenu.............................................................................................. 3-27Table 3-17. DUST SETUP Submenu...................................................................................... 3-28Table 3-18. REVIEW Menu..................................................................................................... 3-29Table 8-1. Diagnostic Indicators ............................................................................................. 8-2Table 8-2. Troubleshooting Chart ........................................................................................... 8-3Table 10-1. Replacement Parts for General Purpose Intelligent Electronics ......................... 10-4Table 10-2. Replacement Parts for Type 4X Intelligent Electronics ....................................... 10-4Table 10-3. Replacement Parts for Transceiver and Retroreflector Modules ........................ 10-4Table 10-4. Replacement Parts for Transceiver Module ........................................................ 10-5Table 10-5. Replacement Parts for Retroreflector Module ..................................................... 10-5Table 10-6. Replacement Parts Kit ......................................................................................... 10-6Table 10-7. Certified Neutral Density Filters ........................................................................... 10-6


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Rosemount Analytical Inc. A Division of Emerson Process Management P-1

Model OPM 2001

PREFACEThe purpose of this manual is to provide information concerning the components, func-tions, installation and maintenance of the Model OPM 2001 Transmissometer Opacity/DustDensity Transmitter.

Some sections may describe equipment not used in your configuration. The user shouldbecome thoroughly familiar with the operation of this module before operating it. Readthis instruction manual completely.

DEFINITIONSThe following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout thispublication.

Highlights an operation or maintenanceprocedure, practice, condition, state-ment, etc. If not strictly observed, couldresult in injury, death, or long-termhealth hazards of personnel.

Highlights an operation or maintenanceprocedure, practice, condition, state-ment, etc. If not strictly observed, couldresult in damage to or destruction ofequipment, or loss of effectiveness.

NOTEHighlights an essential operating procedure,condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERSThe number in the lower right corner of each illustration in this publication is a manual illus-tration number. It is not a part number, and is not related to the illustration in any technicalmanner.


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Model OPM 2001

IMPORTANT

SAFETY INSTRUCTIONSFOR THE WIRING AND INSTALLATION

OF THIS APPARATUSThe following safety instructions apply specifically to all EU member states. They shouldbe strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-EU states should also comply with the following unless superseded by local or NationalStandards.

1. Adequate earth connections should be made to all earthing points, internal and external,where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cableanchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only bemade through a circuit breaker which will disconnect all circuits carrying conductors during afault situation. The circuit breaker may also include a mechanically operated isolating switch.If not, then another means of disconnecting the equipment from the supply must be providedand clearly marked as such. Circuit breakers or switches must comply with a recognizedstandard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazard-ous voltages are likely to be present beneath. These covers should only beremoved when power is removed from the equipment and then only bytrained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is adanger from hot surfaces beneath. These covers should only be removed bytrained service personnel when power is removed from the equipment. Cer-tain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer tothe Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the follow-ing standards: EN61010-1, IEC417, and ISO3864.


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Rosemount Analytical Inc. A Division of Emerson Process Management P-3

Model OPM 2001

GLOSSARY OF TERMSAir WindowA device that blows purge air out of the transceiver and retroreflector module into the stack, pre-venting the stack gasses from entering the modules. This maintains a clean space between themodule optics and flue gasses, preventing particulate buildup on the optics. The air window con-tains a manually sliding seal that is used to isolate the module from the stack when purge airmust be turned off. The air window also contains a ball joint used to align the optics.

Corner CubeA device used by the OPM 2001 as a retroreflector. Corner cubes come in different sizes basedon the path length between the transceiver and retroreflector modules.

EPAEnvironmental Protection Agency.

ExtinctionSee optical density.

FSK (Frequency Shift Keying)The sumperimposing of a high frequency digital communication signal on an electrical signal. TheHART communication protocol uses FSK to communicate between the hand held unit and theintelligent electronics over the 4-20 mA analog output line. The HART signal does not affect the4-20 mA analog output, since no energy is added to or removed from the loop.

HART CommunicatorA hand-held communications and interface device that can communicate with HART compatibleinstrumentation. The HART communicator can be used to view data and configure and calibratethe OPM 2001. The HART communicator uses the frequency shift keying technique to communi-cate to other HART compatible device over the 4-20 mA analog output line.

In SituThe measuring of the parameters of a process without extracting the sample from the processstream.

LCW (Liquid Crystal Window)A solid state device that changes from translucent, scattering and diffusing light, to transparentwhen an electrical signal is applied. This allows the OPM 2001 to control the path of light throughthe transceiver module with no moving parts.

lfThe flange to flange distance between the transceiver and retroreflector modules when installedon the stack.

ltThe inside stack diameter at the transmitter location.

lxThe inside stack diameter at the stack exit.


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Model OPM 2001

lx/ltThe ratio between the inside diameter of the stack at the stack exit and at the transmitter location.This value is used to correct the transmitter reading to calculate stack exit opacity.

Neutral Density FilterAn optical filter used to reduce the intensity of light without changing its color.

OpacityThe amount of light being scattered or absorbed by particles in the path of a beam of light.

Optical Density (OD)The degree of translucence of an optical medium. Optical density is expressed as:OD = -log(transmittance/100). An optical density of 1 is equivalent to a 10% transmittance, or anopacity of 90%. Also called Extinction.

Photopic RegionThat region of the light spectrum visible to the human eye.

Purge AirFiltered air provided by the purge air blowers. Purge air is used by the air windows to prevent thebuild-up of particulate on the module optics.

RetroreflectorA device that reflects light in such a way that its angle is parallel to the incoming, or incident, rays.The OPM 2001 uses a corner cube in the retroreflector module to reflect the light beam from thetransceiver module back to the transceiver module.

Ringelmann ScaleA scale ranging from 0 to 5 used by observers to rate the opacity of stack emissions. Each num-ber on the scale equals approximately 20% opacity, i.e. a Ringelmann number of 2 equals 40%opacity. The Ringelmann scale is very subjective, as it can be influenced by sky haze, the posi-tion of the sun, or interpretation of the observer.

TransmissometerAn instrument that uses opacity to measure the particulate level of stack emissions. Sometimesreferred to as a dust density transmitter.

TransmittanceThe complimentary function of opacity. Percent opacity plus Percent transmittance always equals100%.

Zero JigA device used to provide a zero opacity reference for the OPM 2001 without the need to removethe transceiver module from the stack. Also holds neutral density filters for performing spanchecks.


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Rosemount Analytical Inc. A Division of Emerson Process Management 1-1

Model OPM 2001

SECTION 1DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST OF TYPICALSYSTEM (PACKAGE CONTENTS)

A typical Rosemount Model OPM 2001 Trans-missometer Opacity/Dust Density Transmittershould contain the items shown in Figure 1-1.

1-2 SYSTEM OVERVIEW

a. Scope

This instruction bulletin is designed to sup-ply details needed to install, operate, andmaintain an OPM 2001.

b. Reason for Measuring Opacity

Opacity refers to the amount of light beingscattered or absorbed by particles in thelight beam path. An opacity or dust densitytransmitter (also called a transmissometer)measures the particulate level of stackemissions. One of the most common rea-sons for measuring opacity is to comply withEnvironmental Protection Agency (EPA) orother national requirements. Federal regu-lations for new emission sources and manystate regulations for both new and existingsources specify maximum limits for stackemission opacity.

A transmissometer can be used in a varietyof applications. Those applications includemonitoring the efficiency of emission controlsystems, detecting broken bags in bag-houses, and determining the time rappingcycles for electrostatic precipitators. Anotherapplication is to gauge the effectiveness ofinjecting flue gas conditioning agents usedto improve electrostatic precipitator per-formance.

Opacity data can also serve as a rough in-dicator of combustion efficiency. Extremechanges in opacity may indicate inefficientcombustion or boiler problems. Because the

transmitter gives accurate, immediate-response data, corrective actions can betaken as soon as problems occur. This dataserves not only the compliance requirementof pollution regulation standards but also asa means to achieve improved efficiency andoperating profit.

Originally, a trained smoke reader deter-mined the particulate level of stack emis-sions solely by observation. The opacity ofthe plume was judged in reference to astandard Ringelmann scale of 0 to 5. Thesedeterminations tended to be influenced byseveral sources of error such as sky haze,sun position, and the subjective determina-tion of the observer. These sources of error,especially at lower opacity levels, can pro-duce highly variable readings even whenperformed by a trained observer.

c. System Description

The OPM 2001 is an in situ optical trans-mitter that uses a visible light beam in thephotopic region (peak and mean responsesin the 500 to 600 nm range) to measureopacity in stack emissions. The OPM 2001contains no moving parts except for blowermotors, which eliminates sources of wearand possible failure.

Federal regulations and many state and lo-cal laws use visual observation as a refer-ence. Thus, for a true correlation, it isimportant that transmissometers use thesame spectral response range as the hu-man eye. This portion of the spectrum iscalled the photopic response range. Sincevisual readings are taken at the stack exit,the OPM 2001 compensates for the differ-ence between stack diameter at the exit andstack diameter at the installation site.

The OPM 2001 consists of a transmitter/receiver (transceiver) module, a retrore-flector module, and intelligent electronics.


1-2 Rosemount Analytical Inc. A Division of Emerson Process Management

Model OPM 2001

o

HART Communicator

FISHER-ROSEMOUNTTM

MAN 4275A00English

October 1994

2

115

14

12

13

3

4

9

1110

8

5

6

7 35560026

1. Transceiver Module 2. Retroreflector Module 3. General Purpose Intelligent Electronics 4. Type 4X Intelligent Electronics (optional) 5. Optical Alignment Sight (optional) 6. 6 in. Optical Extension (optional) 7. LON Communication Test Cable 8. Power Supply (optional)

9. 751 Field Signal Indicator (optional) 10. Communication Cable (optional) 11. Purge Air Failure Flow Switch Cable (optional) 12. HART Communications Package (optional) 13. Instruction Bulletin 14. Power Test Cable 15. Zero Jig (optional)

Figure 1-1. Standard Model OPM 2001 TransmissometerOpacity/Dust Density Transmitter


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Model OPM 2001

The transceiver and retroreflector mod-ules are mounted directly opposite ofeach other on the stack (Figure 1-2). Thetransceiver projects a controlled beam oflight across the stack. The corner cubebounces the light back along a parallelpath to the transceiver. Particles in thegas stream cause a certain amount of thelight to be scattered and absorbed. Thisamount varies depending on the particu-late content of the gas stream and theparticle type and size.

The light then strikes a detector, which con-verts the light into a voltage that can be

processed. The detector signal is amplifiedby an independently powered detector/amplifier board. The amplified signal is thendigitized and transmitted to the intelligentelectronics. The intelligent electronics cal-culates opacity, sends commands to thetransceiver, and provides an operator in-terface via HART communications.

Because the beam passes through thestack twice (once in each direction), the re-sulting value is a double-pass transmittancemeasurement. By passing through thesmoke twice, sensitivity to low opacity levelsis increased.

COMMUNICATIONSCABLE TO AND

FROM TRANSCEIVER

STACKEXHAUST

CORNERCUBE

RETROREFLECTOR

WINDOWACCESSPLATE

BEAMSPLITTER

DETECTOR

LAMP

TRANSCEIVERMODULE

OBJECTIVELENS

WINDOW

NOTES: BLOWER MOTORS ARE NOT SHOWN.COMMUNICATIONS CABLE MAY BE UP TO 1 MILE LONG.

HARTCOMMUNICATOR

INTELLIGENTELECTRONICS

35560016

Figure 1-2. Component Relationships



Model OPM 2001

The measurement value is compared to areference value previously determined withno smoke in the light path. The resulting ra-tio is the transmittance value for the meas-urement path. This ratio can then beconverted to units of optical density, stackexit opacity, and dust concentration.

The reference value depends on the lf di-mension shown in Figure 1-3. Also illus-trated are dimensions lx and lt, which arenecessary for OPM 2001 calibration andsetup. These dimensions are defined asfollows:

lx = inside stack diameter at stack exit.lt = inside stack diameter at the trans-

mitter location.lf = flange to flange distance between

the transceiver and retroreflectorunit. It is also the distance that mustbe used to calibrate the unit offline.

The LX/LT parameter is entered in theBASIC SETUP submenu of the HARTCommunicator. See paragraph 3-8c formore information.

Opacity is a complementary function oftransmittance. It is a measurement of theamount of light that is blocked or absorbedby the flue gases. The measurement of

Figure 1-3. Calibration Dimensions

smoke opacity is sometimes referred to inRingelmann numbers. By definition, Ringel-mann No. 1 is equivalent to 20% opacity withthe opacity increasing 20% for each subse-quent number. This scale is based on asingle-pass value as would be read by a hu-man observer.

The relationship between opacity, transmit-tance, and optical density (or extinction) isshown graphically in Figure 1-4 and in thetable in Appendix A. One hundred percenttransmittance is equivalent to 0% opacity orzero optical density. Opacity and opticaldensity are logarithmically related in such away that zero optical density equals zeroopacity; an optical density of one is equal to90% opacity; an optical density of two isequal to 99% opacity, etc.

Figure 1-4. Relationship of Opacity,Transmittance, and Optical Density


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The OPM 2001 automatically compensatesfor the effects of ambient light, zero drift,and component aging with every measure-ment cycle. Four separate voltages pro-duced in each measurement cycle arecompared against two sets of referencevoltages taken either off stack or in a clearstack. The first set is taken in 0% opacityconditions, and the second set is taken insimulated 100% opacity conditions. The re-sulting reference zero and span voltagesproduce a reference point by which thetransmitter judges current operation.

d. System Considerations

All procedures in this manual must be per-formed carefully in order to gain the maxi-mum benefit from the OPM 2001. Propermaintenance is important for maintainingsignal accuracy and will greatly increase in-strument life.

e. Dust Concentration Measurements

The OPM 2001 uses an optical technique tomeasure opacity and extinction. Equatingthis to a dust concentration measurementrequires additional iso-kinetic sampling inorder to calibrate the unit. Iso-kinetic sam-pling involves taking a series of actual dustconcentration measurements in the flue andcomparing these with the extinction readingfrom the OPM 2001. From this comparison,a graph can be plotted (Figure 1-5) thatshows the relationship between extinctionand dust measurement exclusive to thatparticular application. This method takesinto account the variation in dust sizes anddensities in different applications. The pro-cedure is described in the followingstandards:

1. ISO 9096 Stationary Source Emis-sions. Determination of mass

concentration and mass flow rate ofparticulate matter in gas-carrying ducts- manual gravimetric method.

2. ISO/DIS 10155 Stationary SourceEmissions. Automated monitoring ofmass concentration of particles - per-formance characteristics, test methods,and specifications.

Figure 1-5. Example Relationship of Extinctionand Dust Concentration



Model OPM 2001

1-3 METHOD OF MEASUREMENT

The following sequence of steps determines therelationship of dust concentration to extinctionreadings:

a. After the OPM 2001 has been installed andis functioning properly, a series of gra-vimetric measurements are taken using astandard method as outlined in ISO 9096.As each measurement is taken, theequivalent extinction reading on the OPM2001 is recorded.

b. The recorded data is plotted and presentedin accordance with methods outlined in ISO10155 or a relevant local standard. This in-formation is used to calculate the extinctioncoefficient that determines the relationshipbetween extinction and dust concentrationmeasurement.

c. A typical graph and dust concentration cal-culation (Figure 1-5) shows a linear

relationship between extinction and dustconcentration. The calibration curve can belinearized and represented by the followingequation:

DC = kE + c

Where:DC = dust concentrationk = slope of dust concentration by ex-

tinction (determined from stack dustsampling test data)

c = y intercept of dust concentration(determined from stack dust sam-pling test data)

E = Extinction (measured variable byOPM 2001)

The values for k and c are then entered inthe DUST SETUP submenu of the HARTCommunicator to calculate the dust con-centration (DC) from the extinction value.Refer to paragraph 3-9e for moreinformation.


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Model OPM 2001

1-4 SPECIFICATIONSElectrical:

Input Voltage Requirements ......................... 100/115/220/240 VAC, 50/60 HzPower Requirements..................................... 400 watts to transceiver, including 300 watt heater.

The blowers are separately powered and rated at1/2 HP @ 60 Hz or 1/3 HP @ 50 Hz (5.6 A @ 115VAC or 3.1 A @ 240 VAC, 50 Hz).

Wiring ............................................................ Two twisted pair (Belden 8162, 8163, or equivalent);maximum 5000 ft (1524 m) of cable between trans-ceiver and intelligent electronics.

Electrical Classification ................................. Category II

Environmental:Ambient Operating Temperature .................. -40° to 130°F (-40° to 55°C)Flue Gas Temperature .................................. Maximum 1000°F (538°C); Minimum 220°F (104°C);

Non-condensing.Flue Gas Pressure ........................................ Maximum 10 in. (254 mm) WC with supplied blowersPathlength ..................................................... User-definable from 3 to 26 ft (0.9 to 7.9 m)

Physical:Optical System .............................................. Double-pass multiple lens optical system with solid

state electronic light modulation; utilizes liquid crystalwindows.

Light Source .................................................. Gas-filled incandescent bulbSystem Shipping Weight ............................... 356 lbs (161.5 kg)

Transceiver and Retroreflector:Enclosure Type ............................................. Weather housings are moisture-proof. The trans-

ceiver assembly is designed for Type 4Xenvironments.

Dimensions ................................................... Height: 28.77 in. (731 mm)Width: 12.5 in. (318 mm)Depth: 33.94 in. (862 mm)

Weight ........................................................... Transceiver: 80 lbs (36.3 kg)Retroreflector: 40 lbs (18.1 kg)

Optical Alignment Sight................................. Visual alignment sighting indicator utilizing cross-hairs.

Air Lens Assembly:Mounting........................................................ Flange mounted to enclosure mounting plateDimensions ................................................... Diameter: 11 in. (280 mm)

Length: 6 in. (150 mm)Weight: 18 lbs (8 kg)

Blower Motor ................................................. Maximum volume 40.0 cfm @ 10 in. H2OWeight ........................................................... 29 lbs (13 kg)

Intelligent Electronics:Enclosure Type ............................................. General Purpose

Optional Type 4XAmbient Operating Temperature .................. 40° to 120°F (4° to 50°C)

-40° to 120°F (-40° to 50°C) for optional Type 4Xintelligent electronics with heater and thermostat

Dimensions ................................................... Height: 2.72 in. (69.1 mm)Width: 7.00 in. (177.8 mm)Depth: 5.13 in. (130.3 mm)



Model OPM 2001

Weight ........................................................... 10 lbs (4.54 kg)Voltage .......................................................... 24 ±1 VDCPower ............................................................ 25 watts (Optional heater in Type 4X intelligent

electronics adds 300 watts.)Contact Rating .............................................. 30 VDC, 2 A; 110 VDC, 0.3 A; 125 VAC, 0.5 A

Operational:The OPM 2001 meets EPA design and performance requirements as specified in 40 CFR, Part 60, Appen-dix B, Performance Specification 1. The OPM 2001 also meets the performance audit requirements of EPAMethod 203.

Output Ranges .............................................. Continuously adjustable (field adjustable)Accuracy........................................................ ±1% opacity (accuracy of ±1% opacity in normal op-

erating areas, up to 70% opacity reading. Above70% opacity reading, accuracy of ±2% opacity ab-solute).

Resolution ..................................................... <0.1% opacityResponse Time ............................................. <10 secondsCalibration Error ............................................ <2% opacityZero Drift ....................................................... <2% opacity in 3 monthsCalibration Drift ............................................. <2% opacity in 3 monthsSpectral Response........................................ 400 to 700 nm (less than 10% outside of this re-

gion); 500 to 600 nm peak and mean spectralresponse.

Angle of View ................................................ <2 degreesAngle of Projection ........................................ <2 degreesZero Check.................................................... Automatic verificationSpan Check................................................... Automatic verificationCalibration Filter Access ............................... Provided for EPA verificationMeasurement Units ....................................... Opacity, transmittance, optical density, extinction,

and dust concentration.Signal Averaging ........................................... 13 selectable averages: 0.25, 1, 2, 3, 4, 5, 6, 10, 12,

15, 20, 30, and 60 minutes.Automatic Lamp Compensation.................... IncludedAutomatic Calibration Verification ................. User-selectable, 1 to 1440 minutesDigital Input ................................................... Contact input for remote initiation of zero/span checkAnalog Outputs ............................................. Three linear isolated outputs 4-20 mA; 900 ohms

maximum (user-definable).Contact Outputs ............................................ Six SPST relays, including two selectable alarmsDigital Communications Link......................... Communications link between transceiver and intel-

ligent electronics processor, 78 k baud.Selectable Parameters.................................. Measurement units

Signal averagingOptical Path Length Ratio (OPLR)Analog output signal selectionAlarm settingsManual calibrationComputer-assisted EPA filter chec

Certification ................................................... Supplied with Manufacturers EPACertificate of Compliance (option)

Vibration/Expansion Cross Hair Criteria ....... Within circle of 2% opacityVibration Frequency...................................... <60 cpsVibration Frequency Magnitude .................... <0.0025 in. at 60 Hz


July 2001


Model OPM 2001

1-5 SYSTEM STARTUP PROCEDURE

Use the following steps to start the OPM 2001.If the opacity transmitter is installed to meet therequirements of EPA regulation 40 CFR, Part60, Appendix B, Specification 1, follow this pro-cedure prior to installing the opacity transmitteron the stack (see 40 CFR, Part 60, Appendix B,Specification 1, Section 7, PERFORMANCESPECIFICATION VERIFICATION PROCE-DURE). It is also recommended that certainparts of these startup procedures be repeatedonce the unit is mounted on the stack or duct.

a. Turn on power to the transceiver and retro-reflector modules immediately after their in-stallation to the stack or duct. Refer toSection 2 for the complete installation pro-cedure. Turn on the purge air blowers toensure that both the transceiver windowand retroreflector corner cube will be keptdirt free.

b. Turn on the power source to the intelligentelectronics and connect the HART Commu-nicator per paragraph 3-2. Turn on theHART Communicator and select CHECKOPTICS from the DIAG/SERVICE menu.Next, select the VSTACK menu option to placethe OPM 2001 in the check optics mode.

c. Align the transceiver and retroreflector.(Refer to Section 4 for the complete proce-dure.) If the alignment is performed off ofthe stack prior to the installation to meet theprior to installation requirements of 40CFR, Part 60, Appendix B, Specification 1,be sure the transceiver and retroreflectormodules are spaced within 1/4 in. (6.35mm) of the actual installed flange-to-flangedistance. Exit the CHECK OPTICS proce-dure when alignment is complete.

d. Set up the operating parameters in theBASIC SETUP and DETAILED SETUPmenus of the HART Communicator. Referto paragraphs 3-8 and 3-9 for the completesetup procedures.

e. Enter the PROCESS VARIABLES menuand select FLD DEVICE VOLTS per para-graph 3-6a. Four voltages are listed: VSTACK(stack), VLAMP (lamp), VAMB (ambient), andVDARK (dark). Selecting STACK TEMPERA-TURE displays VAD590 (ambient voltage)and TEMP (transceiver electronics tem-perature). These voltages and temperaturereadings indicate the up-to-date levels ofthese measured variables. If the stack orduct is clear of opacity, the stack voltagewill typically be set at 2.0 volts by the fac-tory. The lamp voltage will typically be set at4.0 V.

NOTEThe actual ambient conditions at theinstallation site may not be the sameas the factory conditions at the time oftesting. Therefore, some variations inthese two voltages will be observedbut will not affect the operation of theopacity transmitter.

f. View the opacity reading on the HARTCommunicator display online menu. Ensurethe primary variable (PV) or the secondaryvariable (SV) is set to display opacity. Referto paragraph 3-6b. Under clear stack condi-tions, or with zero jig installed, the opacityshould now read 0.0%. If the opacity read-ing is other than 0.0 ±0.5%, recalibrate theopacity transmitter.

g. Perform an offline calibration per paragraph3-7b. Reference voltages from the last off-line calibration are stored in the REF.VOLTAGES submenu in the DIAG/SERVICE menu. This stored data should berecorded and saved for later referencebefore proceeding with another offlinecalibration.



Model OPM 2001


July 2001


Model OPM 2001

SECTION 2INSTALLATION

Before starting to install this equip-ment, read the Safety instructions forthe wiring and installation of this ap-paratus at the front of this InstructionBulletin. Failure to follow the safetyinstructions could result in seriousinjury or death.

2-1 GENERALProper functioning of the Rosemount OPM 2001Opacity/Dust Density Transmitter depends onproper installation. All procedures in this sectionmust be followed carefully.

2-2 CHOOSING A LOCATIONThe location of the OPM 2001 is important forobtaining maximum accuracy in the reading ofthe stack particulates. Keep in mind both clear-ance and process/regulatory considerationswhen choosing an installation location.

a. Clearance Considerations 1. Ensure the location is accessible and

provides adequate clearance to serviceand maintain the transmitter.

2. Allow 32 in. (813 mm) for clearance oneach side of the stack to remove andinstall the weather housings (Figure2-1).

SYSTEM TO BE INSTALLED PER LOCAL ANDNATIONAL ELECTRIC CODES.

FOR U.S. APPLICATIONS, REFER TO E.P.A.INSTALLATION REQUIREMENTS, 40 CFR 60,APPENDIX B, PERFORMANCE TEST 1.

DIMENSIONS ARE IN INCHES WITHMILLIMETERS IN PARENTHESES.

CONNECT WIRING/CONDUIT PER NATIONALAND LOCAL ELECTRICAL CODE STANDARDS.

POWER REQUIREMENTS:400 WATTS - TRANSCEIVER WITH HEATER400 WATTS - EACH BLOWER

PURGE AIR FAILUREFLOW SWITCH CABLE(10, FIGURE 1-1)(SEE NOTE 5)

TO INTELLIGENTELECTRONICS

CUSTOMER-SUPPLIED SIGNAL CABLE[1 MILE (1.5 KM) MAXIMUM LENGTH]

NOTES:

1.

2.

3.

4.

5.

CONDUIT TOINSTRUMENTENCLOSURE

32 (813) CLEARANCENEEDED TO REMOVE

WEATHER HOUSING(TYP. BOTH SIDES)

35560027

Figure 2-1. Transmitter Location Considerations



Model OPM 2001

3. Locate the transmitter no further thanone mile (1.5 km) from the intelligentelectronics.

b. Regulatory/Process Considerations

The EPA has established the followingguidelines for choosing an opacity/dustdensity transmitter installation site:

1. Locate the transmitter across a sectionof a duct or stack that will provide aparticulate matter flow through the pathof the transmitter beam representativeof the duct or stack flow.

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

3. Locate the transmitter as far frombends and obstructions as practical.

4. If a transmitter is to be located lessthan 4 duct diameters downstreamfrom a bend, install the transmitter inthe plane defined by the bend. SeeFigure 2-2.

Figure 2-2. Transmitter Location

5. Ideally, locate the transmitter eight toten stack diameters upstream from thestack exit and three to five diametersdownstream from any bends, junctions,or other constrictions in the stack orduct.

For best results, mount the transceiverand retroreflector modules so the lightbeam is exactly perpendicular to thestack or duct and the beam goesthrough the center. Do not install thetransmitter downstream of a wetscrubber. The water droplets intro-duced to the gas stream by suchequipment will interfere with the opacityreadings. For an accurate measure-ment under these conditions, choose alocation upstream from a wet scrubberor a location downstream from thescrubber where the water droplets arevaporized by the reheating of the gas.

2-3 CALIBRATION

The OPM 2001 is factory calibrated for theflange-to-flange distance (lf) (Figure 1-3) of theinstallation site. If the unit needs to be recali-brated, refer to paragraph 3-7b. If a Dust Con-centration (DC) output is required afterinstallation, it is necessary to perform iso-kineticsampling on the flue gas while simultaneouslymeasuring the extinction (E) value. Refer toparagraph 1-3 for a description of thisprocedure.

2-4 MOUNTING FLANGES TO STACK

a. Form two mounting holes in the stack atlocations specified in paragraph 2-2. Holesmust be on the same horizontal and verti-cal axes. A liquid level can be used to en-sure that modules are installed on samehorizontal plane.

b. Install 6 in. pipe and 6 in., 150 lb flangesfollowing the notes in Figure 2-3. Pipemust be horizontal and should protrude atleast 4 to 6 in. (102 to 153 mm).


July 2001


Model OPM 2001

37/8 (22) DIA. - 8 HOLESEQUALLY SPACED ON9-1/2 (241) DIA. B.C.

STRADDLING THE VERTICALAND HORIZONTAL CENTERLINES.

11.00(279) O.D.

6.72(171) I.D.

6 IN. 150 LB R.F. (RAISED FLANGE)ANSI FLANGE (B16.5)

SUPPLIED BY CUSTOMER

6

4

FIELD WELDPIPE TOFLANGE

4 (102)MINIMUM

CLEARANCETYPICAL

MASONRY STACKWALL INSTALLATION

METAL WALL STACKOR DUCT INSTALLATION

6-5/8 (168)O.D. REF.

6 IN. SCHED. 40PIPE SUPPLIEDBY CUSTOMER

5

6

3STUD ANCHORS

OUTSIDE WALLSURFACE

FIELD WELDPIPE TO

FLANGE ANDMETAL STACK

OR DUCTWALL

NOTES:

WHEN FLUE GAS TEMPERATURE IS LESS THAN600 F (316 C), INSULATE AND LAG THIS AREA TOPREVENT CONDENSATION AND CORROSION.

° °3.

ALL MATERIAL AND FIELD WORK ARE PROVIDEDBY THE CUSTOMER TO INSTALL THE TRANSCEIVERAND RETROREFLECTOR MODULES OF THE OPACITYMONITOR.

2.

EXTEND INSULATION ON METAL STACK ORDUCT SURFACES TO 24 IN. (610 MM). THIS WILLPREVENT RADIANT HEAT FROM DAMAGINGTHE OPACITY MONITOR.

5.

WHEN FLUE GAS TEMPERATURE EXCEEDS 600 F(316 C), INSERT AN INSULATING GASKET SUCHAS MANUFACTURED BY BNZ MATERIALS, INC.RECOMMENDED GASKET MATERIAL IS MARINITEP, AT LEAST 1 IN. (25 MM) THICK. REFER TOPARAGRAPH 2-7b1 REGARDING THERMOISOLATORS.

°°

6.

1. DIMENSIONS ARE IN INCHES WITHMILLIMETERS IN PARENTHESES.

4. A BLANK 11.0 IN. (279 MM) O.D. BLIND 150 LB FLANGEDRILLED TO A 6.72 IN. (171 MM) I.D. AND DRILLEDAND TAPPED TO 0.75 - 16 UNF (M20) - 8 HOLESEQUALLY SPACED ON 9.50 IN. (241 MM) DIA. B.C. MAYBE SUBSTITUTED FOR THE 6 IN. 150 LB RF FLANGE.

35560022

Figure 2-3. Stack Flange Installation

c. Weld a flange to each pipe. Align flangesso that they are relative to a commoncenterline. Total module deviation shouldnot exceed ±5 degrees. Deviation withinthis limit can be compensated for by theair lens ball joint adjustment.

2-5 LIFTING AND HANDLING

Use the following procedure to hoist the mod-ules to the installation site and mount them tothe stack:

a. Remove the weather housings by releasingfour toggle clamps (5, Figure 2-4) that holdeach housing to the mounting plate.

b. Remove transceiver optical assembly or ret-roreflector from air lens assembly (Figures5-1 and 5-12).

c. Run a lifting sling through the air lensopening in the mounting plate (Figure 2-4).Make sure all hooking devices are secure.Lift the mounting plate assembly to the in-stallation site.



Model OPM 2001

35560028

TO MOUNT ON STACK, REMOVE WEATHER HOUSING(1) AND OPTICAL ASSEMBLY (2). LIFT MOUNTINGPLATE ASSEMBLY (3) BY SLING (4) THROUGH THEAIR WINDOW.

AIR LENS SEAL PLATE (6) MUST REMAIN CLOSEDUNTIL THE BLOWER MOTORS ARE POWERED.

HANDLING PROCEDURE

65 4

2

31

Figure 2-4. Lifting and Handling

2-6 MOUNTING INSTRUCTIONS

a. Transceiver and Retroreflector Modules

1. Install customer-supplied 0.75-16 boltsin the stack mounted spool piece andflange for the mounting plate per Fig-ures 2-3 and 2-5.

2. Make sure heat-resistant gasket (32,Figure 5-1) is installed between eachmodule and its stack flange. Attacheach module to the four bolts installedin each stack flange and secure withfour customer-supplied washers andnuts.

3. Install stabilizers to provide firm sup-port for each module and secure withcustomer-supplied bolts, nuts, andwashers from the inside of the mount-ing plate (Figure 2-5).

Shutter must remain closed until theblower is powered up.

4. Close air lens assembly shutter (sealplate) (6, Figure 2-4) until the blowersare powered up.

5. Install the transceiver optical assemblyand retroreflector to the mountingplates and install the weather housingsto the modules (Figure 2-5).

b. Intelligent Electronics

The outline drawings in Figure 2-6 show themounting centers and clearances for thetwo versions of the intelligent electronics.


July 2001


Model OPM 2001

A

A

TRANSCEIVER RETROREFLECTOR

STACK

TYPICAL PLAN VIEW

6.25(159)

0.81 (21) DIA.(4 PLCS) SPACED

ON 9.50 (241)DIA. B.C. (SEE

NOTE 4 ANDNOTE 5)

4.62 (117)SQUARE OPENING

(SEE NOTE 2)

7.00(178)

3.50(89)

22.27(566)

28.77(731)

SECTION A-A

CUSTOMER-SUPPLIEDSTABILIZERS

(2 REQUIRED)

CUSTOMER-SUPPLIED MOUNTING

SPOOL PIECEAND FLANGE

4 (102)MIN. ORLARGERAS SPECIFIEDOR INSTALLEDBY CUSTOMER

WIRINGCONDUIT

33.94(862)

FLUEGAS

FLOW

TOGGLECLAMP

(SEE NOTE 3)B

CUSTOMER-SUPPLIED

STABILIZERS(2 REQUIRED)

0.75-16 UNF ANCHOR STUD

STABILIZER

MOUNTINGPLATE

STABILIZERLENGTH

TO BE 1/8 (0.125)LESS THAN

DIMENSION X

STACK

VIEW B

NOTES:

1. DIMENSIONS ARE IN INCHES WITHMILLIMETERS IN PARENTHESES.

2. MOUNTING PLATE OPENING TO STACK.

3. FOUR TOGGLE CLAMPS ARE PROVIDEDTO ATTACH MOUNTING PLATE TOWEATHER HOUSING.

4.

5.

0.75-16 UNF X 3.0 (M20 X 75 MM) HEX HEADBOLTS WITH WASHERS AND NUTS(CUSTOMER-SUPPLIED) REQUIRED TO ATTACHINSTRUMENT TO 6 IN. 150 LB ANSI FLANGE.

BOLT HOLE PATTERN TO CUSTOMER FLANGESTRADDLES THE CENTERLINE. MOUNTINGFLANGE AND BOLTS ARE CUSTOMER-SUPPLIED.

6.

7.

SYSTEM TO BE INSTALLED PER LOCAL ANDNATIONAL ELECTRIC CODES.

FOR U.S. APPLICATIONS, REFER TO E.P.AINSTALLATION REQUIREMENTS, 40CFR60,APPENDIX B, PERFORMANCE TEST 1.

16.13(410)

29170009

12.50(318)

0.81 (21)CLEARANCE

HOLES (2 PLCS)FOR STABILIZERS

0.88 (22) CLEARANCE(4 PLCS)HOLES

FOR CUSTOMERWIRING

X

12.50(318)

22.5°

Figure 2-5. Stack Installation Dimensions



Model OPM 2001

6.00 (152)

4.69(119)

1.56(40) LON AND 4-20 mA

COMMUNICATIONS

DIGITALINPUT

RELAYSPOWER

ANALOGOUTPUTS

5.19 (132)

4.71(120)

5.13(130)

2.72(69)

7.00 (178)

0.57 (14)

0.177(4)

DIMENSIONS ARE IN INCHESWITH MILLIMETERS IN PARENTHESES.

NOTE:

TYPE 4X INTELLIGENT ELECTRONICSGENERAL PURPOSE INTELLIGENT ELECTRONICS

12.50(318)

8.00(203)

11.00(279)

12.94(329)

0.31 (8) x 0.50 (13)SLOT

29170014

Figure 2-6. Intelligent Electronics Mounting Dimensions


July 2001


Model OPM 2001

1. General Purpose Intelligent Electronics

(a) Install the general purpose intelli-gent electronics no further than 1mile (1.5 km) from the stack-mounted transceiver unit.

(b) Due to the type of enclosure, thegeneral purpose unit must be in-stalled indoors where the ambienttemperature is between 40° to120°F (4° to 50°C).

(c) If mounting the unit on a wall orbulkhead, use cable clamps andstraps on the wiring as needed toavoid straining the connections.

2. Type 4X Intelligent Electronics

(a) Mount the Type 4X intelligentelectronics to a wall or bulkhead nofurther than 1 mile (1.5 km) fromthe stack-mounted transceiver unit.

(b) Locate units without the optionalheater where the ambient tem-perature is between 40° to 120°F(4° to 50°C). For units with the op-tional heater, install where the am-bient temperature is between -40°to 120°F (-40° to 50°C). Keep inmind that the Type 4X version canalso be installed outdoors.

c. Model 751 Indicator (Optional)

If using the Model 751 indicator, mount inan accessible location per the instructions indocument PDS 4378A00.

2-7 MONITORING OPACITY IN HIGHTEMPERATURE APPLICATIONS

a. Introduction

Measuring opacity in high temperature ap-plications such as incinerators can be det-rimental to the physical well-being of opacitytransmitters. Flue gases from incineratorsapproach 2000°F (1093°C). Opacity trans-mitters have reportedly melted at thesehigh temperatures.

Other less severe temperatures just over400°F (204°C) can also cause opacitytransmitter operation problems. In theseapplications, the opacity transmitter ismounted to a steel duct or steel stack. Ra-diant heat from the duct or stack can causethe temperature within the transceiver andretroreflector modules to exceed ambienttemperature limits.

b. Solution

The heat at the opacity transmitter must bereduced to permit accurate opacity moni-toring in these applications. RosemountAnalytical offers several solutions to helpwith these applications.

1. Thermo Isolators. Thermo isolatorsshould be used whenever the stacktemperature is above 600°F (316°C):for example, incinerator and hot steelstack applications. They provide aheat-resistant barrier between thestack and opacity transmitter flanges.Thermo isolators are a must with thehigher temperature incinerators.



Model OPM 2001

Rosemount Analytical offers thermoisolators for the OPM 2001s 6 in.mounting flanges. This 1 in. (25.4 mm)thick high-temperature gasket providessufficient thermo isolation to withstandhot face temperatures of 1700° to1800°F (927° to 982°C). Two thermoisolators are required for each OPM2001. Remember to add 2 in. (51 mm)to the flange-to-flange dimension (lf)when thermo isolators are used.

In addition, insulation and a cooling fin(Figure 2-7) can be installed betweenthe duct and the opacity transmitter to

ward off radiant heat. This barrier isrecommended for high radiant heatapplications as found in incineratorsand hot steel stacks.

2. Purge Air. A duct or stack maximumpressure is limited to plus 10 in. WC inorder to supply a minimum flow of40 SCFM purge air. These constraintsmust also be adhered to for this appli-cation to be successful. A flow of coolpurge air must be maintained or theopacity transmitter may suffer heatdamage.

INSULATION

FLANGE

COOLING FINAND HEAT SHIELDINSULATION

4 TO 6 IN.(102 TO 152 MM)

12 IN.(305 MM)MINIMUM

INSULATION

SIDE VIEW FRONT VIEW

STACK

STACK

OPM2000R

35560029

12 IN.(305 MM)MINIMUM

Figure 2-7. Insulation and Cooling Fin Installation


July 2001


Model OPM 2001

2-8 MONITORING OPACITY ATLOW AMBIENT TEMPERATURES

a. Introduction

Measuring opacity in locations where ambi-ent temperatures can be expected to gobelow -20°F (-28.9°C) can cause falsereadings as a result of the extremely coldambient air being used by the purge airblowers. When extremely cold purge airmixes with the hot process gases, foggingcan occur. This phenomenon takes place atthe outlet of the purge air window assemblyand directly in the path of the opacity meas-urement. As a result, the opacity reading isfalsely represented as a higher than ex-pected value due to the presence of the fog.

b. Solution

The OPM 2001 can be ordered and/or fieldretrofitted with purge air heaters. Thisheater mounts between the blower and thepurge air window assembly in place of thecheck valve and elevates the temperatureof the purge air to prevent fogging. Refer toFigure 2-8.

2-9 SYSTEM WIRING INSTALLATION

a. Wiring Practices

The wire selected for supplying power to theintelligent electronics and modules must besized to meet the current carrying require-ments (capacity) for the application. Referto the specifications in paragraph 1-4. TheNational Electrical Code contains tables thatmay be used as a guide. Voltage classifica-tion must be equal to or exceed the ratedcircuitry voltage.

All customer-supplied wiring must conformto standard wiring practices in accordancewith local code. The wire must be able towithstand the physical stresses to which itmay be subjected during installation.

NOTEIf wiring an OPM 2001 with a generalpurpose intelligent electronics, refer toFigure 2-9. If wiring an OPM 2001 witha Type 4X intelligent electronics, referto Figure 2-10.

b. Transceiver Module

Refer to Figure 2-9 or Figure 2-10 asappropriate.

1. Make sure communications cable (3,Figure 5-1) from the transceiver isplugged into connector J2 on the stacktermination board.

2. Make sure power cable (2, Figure 5-1)from the transceiver is plugged intoconnector J4 on the stack terminationboard.

3. Attach the customer-supplied signalcable to HART and LON connectors J1and J5 on the stack termination board.Run the cable through the cable grip inthe mounting plate and tighten the sealonto the cable.

Check transceiver data plate for theactual voltage rating. Failure to con-nect the power cable to the appropri-ate power source will damageequipment.

4. Make sure cable (53, Figure 5-1) fromthe transceiver purge air failure flowswitch is connected to PR SW 1 con-nector J7 on the stack terminationboard.



Model OPM 2001

5. Attach a line voltage power cable to ACIN connector J3 on the stack termina-tion board. Run the cable through thecable grip in the mounting plate.Tighten the seal onto the cable. Con-nect the power cable to a suitable linevoltage power source.

6. Refer to paragraph 3-2 for the proce-dure to connect the HART communi-cator to the 4-20 mA signal loop at thetransceiver location.

120 VOLT BLOWERMOTOR JUNCTION

BOX

BLK

GRNWHT

BLU

YEL

WHT

115 VACHEATER

THERMOSTAT55 F (13 C) CLOSE70 F (21 C) OPEN

° °° °

BLK

GRN YEL

BLU

WHT

240 VOLT BLOWERMOTOR JUNCTION

BOX

HEATERWIRE

HEATERWIRE

35560030

BLKBLK

GRNGRN

WHTWHT

NOTES:

1. REMOVE COPPER CHECK VALVE FROM AIRWINDOW THEN INSTALL HEATER IN SAMELOCATION.

2. 40 AMP BREAKER REQUIRED.3. AIR WINDOW ALIGNMENT NUTS MAY NEED TO BE

LOOSENED SO AIR HEATER ASSEMBLY CAN SWINGCLEAR OF OBSTACLES AS IT IS SCREWED INTO AIRWINDOW.

4. REALIGN TRANSCEIVER AFTER INSTALLATION OFAIR HEATER.

AIR WINDOW

220 VACHEATER

Figure 2-8. Optional Purge Air Heater


July 2001


Model OPM 2001

c. Retroreflector Module

Refer to Figure 2-9 or Figure 2-10 as ap-propriate. Run a customer-supplied cablefrom PR SW 2 connector J8 on the trans-ceiver stack termination board through acable grip in the transceiver mounting plateto the purge air failure flow switch in the ret-roreflector module as shown in Figure 2-1.Tighten both seals at each end of the cable.Connect the wires to the retroreflector purgeair failure flow switch.

d. Blower Motor

Refer to Figure 2-9 or Figure 2-10 asappropriate.

NOTEThe retroreflector blower motor has itsown independent power source but iswired the same as the transceiverblower motor at the motor junctionbox.

1. Run a line voltage power cable, de-pending on the system application,through a cable grip on the retrore-flector mounting plate to the retrore-flector blower motor.

2. Connect the wires at the blower motorjunction box.

3. Tighten the cable seal.

e. General Purpose Intelligent ElectronicsRefer to Figure 2-9.

NOTERelay jumper blocks J9 and J11 on theHART daughter board can be config-ured for either the default or failsafeconfiguration. For more information,refer to Section 6, INTELLIGENTELECTRONICS.

1. Run the customer-supplied signal ca-ble through a suitable conduit.

2. Connect the signal cable to the 4-20 mA TO STACK and LON connec-tors on the intelligent electronics.

Check the intelligent electronics dataplate for the required intelligent elec-tronics voltage. Connecting the unit tothe wrong supply voltage will damagethe equipment.

3. Attach a customer-supplied 24 VDCpower cable to the two +24 V connec-tors on the unit. If a 24 VDC powersource is not available, attach the op-tional universal power supply to the two+24 VDC connectors and plug thepower supply into the customer-supplied voltage source.

4. Connect a customer-supplied digitalinput cable for remote initialization ofzero/span checks to the DIGITALINPUT connector on the intelligentelectronics.



Model OPM 2001

B

RD

BL

K

WH

BL

K

SH

IEL

D

A

C

RD

GRN/YLW

GRN/YLW

BLK

WH

WH

WH

BLK

BLK

BL

K

WH

GR

N/Y

LW

BLK

SHIELD

TRANSCEIVERPURGE AIR FAILURE

FLOW SWITCH(SEE NOTE 1)

COMMUNICATIONLINK TO TRANSCEIVER

COMMUNICATIONSCABLE

CONNECTIONSFOR HART

COMMUNICATOR

POWER TO J7ON STACK

LON BOARD

STACKTERMINATION

BOARD

CUSTOMER-SUPPLIED

SIGNAL CABLE

AC POWERCUSTOMER

WIRING

AC POWERCUSTOMER WIRING

TO INTELLIGENT ELECTRONICS

TO RETROREFLECTOR PURGEAIR FAILURE FLOW SWITCH

CABLE GRIP

MOUNTING PANEL

J9 CONNECTS TOGROUND ON

MOUNTING PANEL

2. THE OPTIONAL 751 INDICATORCAN BE LOCATED ANYWHERE INTHE 4-20 mA SIGNAL LINE.

1.

NOTES:

BOTH PURGE AIR FAILURE FLOWSWITCHES ARE WIRED THE SAME.HOWEVER, THE RETROREFLECTORPURGE AIR FAILURE FLOW SWITCHMUST BE WIRED IN THE FIELD,WHEREAS THE TRANSCEIVERPURGE AIR FAILURE FLOW SWITCHIS PRE-WIRED AT THE FACTORY.

35560021

OPTIONAL 751 INDICATOR(SEE NOTE 2)

+ +

+ +

%

Figure 2-9. Customer Connections for OPM 2001with General Purpose Intelligent Electronics (Sheet 1 of 2)


July 2001


Model OPM 2001

4-20mATO STACK

DIGITAL INPUT

+24V

+24VLON

FA

ULT

LE

D

CO

MM

LE

D

PO

WE

RL

ED

WHT

GENERAL PURPOSEINTELLIGENT ELECTRONICS

BLK

24 VDCCUSTOMER WIRINGOR OPTIONAL 24 VDCPOWER SUPPLY

GRN/YLW GRN/YLW

YLW

GRN/YLW

YLW

35560031

BLK

BLKBRN

ORNORN

BRN

BLU BLU

BLKBLK

BLKWHT

WHT WHT

WHT

WHT

SHIELD

BLK

WH

BLK

RD

3.

NOTES:

4.

(SEE NOTES 3 AND 4)

Figure 2-9. Customer Connections for OPM 2001with General Purpose Intelligent Electronics (Sheet 2 of 2)



Model OPM 2001

B

A

RD

GRN/YLW

GRN/YLW

BLK

WH

WH

WH

BLK

BLK

BL

K

WH

GR

N/Y

LW

BLK

SHIELD

TRANSCEIVERPURGE AIR FAILURE

FLOW SWITCH(SEE NOTE 1)

COMMUNICATIONLINK TO TRANSCEIVER

COMMUNICATIONSCABLE

CONNECTIONSFOR HART

COMMUNICATOR

POWER TO J7ON STACK

LON BOARD

STACKTERMINATIONBOARD

CUSTOMER-SUPPLIED

SIGNAL CABLE

AC POWERCUSTOMER

WIRING

AC POWERCUSTOMER WIRING

TO INTELLIGENT ELECTRONICS

RETROREFLECTOR PURGEAIR FAILURE FLOW SWITCH

(SEE NOTE 1)

CABLEGRIPMOUNTING

PANEL

J9 CONNECTS TOGROUND ON

MOUNTING PANEL

29170004

WHT

GRN/YLW

BLK RD

BL

K

WH

BL

K

SH

IEL

D NOTE 2: THE OPTIONAL 751 INDICATORCAN BE LOCATED ANYWHEREIN THE 4-20 mA SIGNAL LINE.

OPTIONAL751 INDICATOR(SEE NOTE 2)

+ +

+ +

%

NOTE 1: BOTH PURGE AIR FAILURE FLOWSWITCHES ARE WIRED THE SAME.HOWEVER, THE RETROREFLECTORPURGE AIR FAILURE FLOW SWITCHMUST BE WIRED IN THE FIELD,WHEREAS THE TRANSCEIVER PURGEAIR FAILURE FLOW SWITCH ISPRE-WIRED AT THE FACTORY.

Figure 2-10. Customer Connections for OPM 2001with Optional Type 4X Intelligent Electronics (Sheet 1 of 2)


July 2001


Model OPM 2001

GREEN/YELLOW

GREEN/YELLOW

YLW

BRN BRNBLK

BLKWHT

ORNORN

BLU BLU

BLK BLK

GRN/YLW GRN/YLWWHT WHT

TRANSCEIVERBLOWER MOTORJUNCTION BOXG02 - 220/240 VAC

YLW

WHT

NOTE 3: BLOWER MOTORWIRING IS BASED ONVOLTAGE SUPPLIED.

RELAYS(TOP CONNECTOR)

PIN 1 - K1+PIN 2 - K1-PIN 3 - K2+PIN 4 - K2-PIN 5 - K3+PIN 6 - K3-

ANALOG OUTPUTSPIN 1 - AOUT1+PIN 2 - AOUT1-PIN 3 - EARTH GNDPIN 4 - AOUT2+PIN 5 - AOUT2-PIN 6 - EARTH GNDPIN 7 - AOUT3+PIN 8 - AOUT3-PIN 9 - EARTH GND

RELA

RELAYJUMPER BLOCKS

YS(BOTTOMCONNECTOR)PIN 1 - K4+PIN 2 - K4-PIN 3 - K5+PIN 4 - K5-PIN 5 - K6+PIN 6 - K6-

HART DAUGHTER BOARD

J8

1

1 (+)24 VDC

2

LON

U4

2 ( - )

3 (EARTH GND)

IG-1 SOFTWARE BOARD

FACTORY WIREDTO POWER SUPPLY

FACTORY WIREDTO RS-232CONNECTORJ8 ON HARTDAUGHTERBOARD

WHT

SHIELD

BLK

A

B

F15A, 250VACSLO BLO

AC POWER CUSTOMER WIRING(115 OR 220 VAC, 50/60 HZ)

J2 J3

N NL L

J1

L N

!

FACTORY WIREDTO POWER SUPPLY

FACTORY WIREDTO HEATER

(SEE NOTES 3 AND 4)

TERMINATIONBOARD

DIGITALINPUT

RD

BLK

35560032

FACTORYWIRED

TO POWERSUPPLY

TYPE 4X INTELLIGENT ELECTRONICS ENCLOSURE

4-20mALOOPTO STACK

RELAYCONTACTS

RELAY 6

RELAY 5

RELAY 2

RELAY 1

1

2

3

RELAY 3

RELAY 4

ANALOGOUTPUTS

DIGITALINPUT

J5

J2

J1

J11

P1P1

J9

J6

J3

U7

3D39650G REV

24VDC

+

+

+

+

+

HART

J7

+

+

+

+

-

-

-

-

-

-

-

-

-

J4

RS-232

J8

+

+

+

+

+

+

+

+

+

+

+

+

+

NOTE 4: THE RETROREFLECTOR MOTORCONNECTS TO ITS OWN POWERSOURCE BUT IS WIRED THESAME AS THE TRANSCEIVERBLOWER MOTOR.

TRANSCEIVERBLOWER MOTORJUNCTION BOXG01 - 110/115 VAC

F11/2ASLO BLO

Figure 2-10. Customer Connections for OPM 2001with Optional Type 4X Intelligent Electronics (Sheet 2 of 2)



Model OPM 2001

HART

RELAYSANALOG OUTPUTS

NOT USED

1 1 2 2 3 3

4 4 5 5 6 6

1 1 2 2 3 3

ANALOG OUTPUTS

PIN 1 - AOUT1+PIN 2 - AOUT1-PIN 3 - EARTH GNDPIN 4 - AOUT2+PIN 5 - AOUT2-PIN 6 - EARTH GNDPIN 7 - AOUT3+PIN 8 - AOUT3-PIN 9 - EARTH GND

RELAYS(TOP CONN)


RELAYS (BOTTOM CONN)


35560035

Figure 2-11. General Purpose IntelligentElectronics Relay and Analog Output Connections

f. Type 4X Intelligent Electronics (Optional)

NOTERelay jumper blocks J9 and J11 on theHART daughter board (Figure 2-10)can be configured for either the de-fault or failsafe configuration. Formore information, refer to Section 6,INTELLIGENT ELECTRONICS.

1. Run the customer-supplied signal ca-ble through a suitable conduit.

2. Run the signal cable through the cablegrip specified in Figure 2-6.

3. Connect the signal cable to the LONconnector on the IG-1 software boardand the 4-20 mA LOOP TO STACKconnector on the HART daughter boardas shown in Figure 2-10.

4. Once the cable is connected, tightenthe cable seal.

Check the intelligent electronics dataplate for the required intelligent elec-tronics voltage. Connecting the unit tothe wrong supply voltage will damagethe equipment.

5. Run a customer-supplied 115 VAC or220 VAC power cable, depending onthe power source, through the cablegrip specified in Figure 2-6. Connectthe power cable to connector J1 on theType 4X intelligent electronics termina-tion board as shown in Figure 2-10.Once the cable is connected, tightenthe cable seal.

6. Make sure connector J2 on the Type4X intelligent electronics terminationboard connects to power supply con-nector SK1.

7. Make sure power supply connectorSK2 connects to the 24 V connectorson the IG-1 software board and HARTdaughter board.

8. If the optional heater is installed, makesure connector J3 on the Type 4X in-telligent electronics termination boardconnects to the heater.

9. Run a customer-supplied digital inputcable for remote initialization ofzero/span checks through the cablegrip specified in Figure 2-6. Connectthe cable to the DIGITAL INPUT con-nector on the HART daughter board asshown in Figure 2-10. Once the cableis connected, tighten the cable seal.

10. Run a customer-supplied relay outputcable through the cable grip specifiedin Figure 2-6. Connect the cable to theRELAY CONTACTS connector on theHART daughter board. Refer to Figure2-10 to match the terminals to the relayfunctions. Once the cable is connected,tighten the cable seal.

11. Run a customer-supplied analog outputcable through the cable grip specifiedin Figure 2-6. Connect the cable to theANALOG OUTPUTS connector on theHART daughter board. Once the cableis connected, tighten the cable seal.

g. Model 751 Indicator (Optional)

Attach the Model 751 indicator in series withthe 4-20 mA signal loop. See Figure 2-10.


July 2001


Model OPM 2001

SECTION 3OPERATION

3-1 OVERVIEW

The HART Communicator is a hand-held com-munications interface device. It provides the op-erator interface to the OPM 2001. Its 8 line x 21character liquid crystal display (LCD) and 25keys are used to view data and to configure andcalibrate the unit. A pocket-sized manual is alsoincluded with the HART Communicator that de-tails the specific functions of all the keys.

The HART Communicator accomplishes its taskusing a frequency shift keying (FSK) technique.With the use of FSK, high-frequency digitalcommunication signals are superimposed onthe 4-20 mA transmitter current loop. The com-municator does not disturb the 4-20 mA signalssince no net energy is added to the loop.

To interface with the OPM 2001, the HARTCommunicator requires a termination pointalong the 4-20 mA current loop and a minimumload resistance of 250 ohms between the com-municator and the power supply. To simplify theconnection procedure, the OPM 2001 providestwo banana jacks at each of the transceiver andintelligent electronics sites so the HART Com-municator can be used at either location asshown in Figure 3-1.

3-2 HART COMMUNICATOR SIGNAL LINECONNECTIONS

There are two methods of connecting the HARTCommunicator to the signal line. For applica-tions in which the signal line has a load resis-tance of 250 ohms or more, refer to method 1.For applications in which signal line load resis-tance is less than 250 ohms, refer to method 2.

a. Method 1, for Load Resistance≥≥≥≥ 250 Ohms

Explosions can result in death or seri-ous injury. Do not make connectionsto the HART Communicators serialport, 4-20 mA signal line, or NiCad re-charger jack in an explosive atmos-phere.

1. If attaching the HART Communicator toan OPM 2001 using the banana jacksprovided at the stack termination boardor the intelligent electronics, refer toFigure 3-1 and the following procedure.

(a) Connect the supplied lead set tothe loop connectors on the HARTCommunicator top panel.

(b) Connect the opposite end of thelead set to the banana jacks oneither the intelligent electronics orthe stack termination board.

2. If attaching the HART Communicator toan OPM 2001 using a wiring termina-tion point in the analog output (AO1)4-20 mA signal line, refer to Figure 3-2and the following procedure:

(a) Connect the supplied lead set tothe loop connectors on the HARTCommunicator top panel.

(b) Using the banana clips suppliedwith the lead set, connect theHART Communicator in parallel tothe load resistance.



Model OPM 20011 1 2 2 3 3 J6

J7

J2

J6

J7

HART TERMINATION BOARD

LOAD RESISTANCE (R )L LOAD RESISTANCE (R )L

TOP COVER PLATE

J1

J2 J3

ANALOG OUTPUTDEVICE

ANALOG OUTPUTDEVICE

OPTIONAL TYPE 4XINTELLIGENT ELECTRONICS


FRONT VIEW

4-20 mASIGNAL LINE 4-20 mA

SIGNAL LINE

4-20 mASIGNAL LINE 4-20 mA

SIGNAL LINE

NOTE: BOARD DETAILS WEREOMITTED FOR CLARITY.

BACK VIEW

LEAD SET

LEAD SET

LEAD SET

J1

J6 J10

STACK TERMINATION BOARD

HART COMMUNICATORTOP PANEL

HARTCOMMUNICATOR

LOOPCONNECTORS

29170018

250 OHM LOAD RESISTOR(ONLY USED IF RL < 250 OHMS)

LEAD SET

LOOP CONNECTORS USE INTERFACE

00275 0013 ONLYSERIAL PORT & BATTERY

CHARGER MUST

NOT BE USED IN

HAZARDOUS AREAS

SERIAL PORT

HART

RELAYS

ANALOG OUTPUTS

NOT USED

1 1 2 2 3 3

4 4 5 5 6 6

3D39650G3D39650G REV

24VDC

+

-

+

-

HART

ANALOG

OUTPUTS

+

-

+

-

+

-

RELAY

CONTACTSCONTACTS

DIGITAL

INPUT

+

-

4-20mA4-20mA

LOOP

TO STACKTO STACK

+

-

4-20mATO STACK

DIGITAL INPUT

+24V

+24VLON

FA

ULT

LE

D

CO

MM

ON

LE

D

PO

WE

RL

ED

TRANSCEIVER

Figure 3-1. HART Terminal Connections


July 2001


Model OPM 2001

HARTRELAYS

ANALOG OUTPUTS

NOT USED1 1 2 2 3 3

4 4 5 5 6 6

1 1 2 2 3 3

ANALOG OUTPUT DEVICE

LEAD SET

LOOP CONNECTORSUSE INTERFACE


CHARGER MUST

NOT BE USED IN

HAZARDOUS AREAS

SERIAL PORT

LOOPCONNECTORS


HARTCOMMUNICATOR

24670049

R 250L Ω>


4-20 mA SIGNAL LINE

Figure 3-2. Signal Line Connections, ≥≥≥≥250 Ohms Lead Resistance

b. Method 2, for Load Resistance< 250 Ohms

Explosions can result in death or seri-ous injury. Do not make connectionsto the HART Communicators serialport, 4-20 mA signal line, or NiCad re-charger jack in an explosiveatmosphere.

1. If attaching the HART Communicator toan OPM 2001 using the banana jacksprovided at the stack termination boardor the intelligent electronics, refer toFigure 3-1 and the following procedure:

(a) Connect a 250 ohm load resistor tothe loop connectors on the HARTCommunicator top panel.

(b) Connect the supplied lead set to the250 ohm load resistor and to thebanana jacks on either the intelli-gent electronics or the stack termi-nation board.

2. If attaching the HART Communicator toan OPM 2001 using a wiring termina-tion point in the analog output (AO1)4-20 mA signal line, refer to Figure 3-3and the following procedure:

(a) Connect a 250 ohm load resistor tothe loop connectors on the HARTCommunicator top panel.

(b) Connect the supplied lead set tothe 250 ohm load resistor.

(c) At a convenient point, break theanalog output (AO1) 4-20 mA sig-nal line and, using the banana clipssupplied with the lead set, connectthe HART Communicator to the4-20 mA signal line.



Model OPM 2001

250ΩRL

>

LEAD SET

250 OHM LOADRESISTOR (SEE NOTE)

HARTCOMMUNICATOR

4-20 mA SIGNAL LINE


24670065

NOTE: THE SIGNAL LOOP MUST BEBROKEN TO INSERT THEOPTIONAL 250 OHM LOADRESISTOR.

THE 250 OHM LOADRESISTOR IS ONLY USEDIF R < 250 OHMS.L

LOOP CONNECTORSUSE INTERFACE


CHARGER MUST

NOT BE USED IN

HAZARDOUS AREAS

SERIAL PORT

HARTRELAYS

ANALOG OUTPUTS

NOT USED

1 1 2 2 3 3

4 4 5 5 6 6

1 1 2 2 3 3

ANALOG OUTPUT DEVICE

LOOPCONNECTORS


Figure 3-3. Signal Line Connections, <250 Ohms Lead Resistance

3-3 OFFLINE AND ONLINE OPERATIONSThe HART Communicator can be operated bothoffline and online.

a. In the online mode, the communicator isconnected to the 4-20 mA analog outputsignal line. The communicator is connectedin parallel to the OPM 2001 or in parallel tothe 250 ohm load resistor.

b. Offline operations are those in which thecommunicator is not connected to the OPM2001.

3-4 HART OPERATOR INTERFACEDESCRIPTIONThe HART Communicator (Figure 3-4) has an8-line, 21-character liquid crystal display (LCD)and 25 keys that provide communication be-tween you and the OPM 2001.

a. LCD Display

When connected to a HART Communicator,the top line of each online menu displays

!"

A B C D E F G H I

J K L M N O P Q R

S T U V W X Y Z /

# % & < > : +*0 . _

1 2 3

4 5 6

7 8 9

F1 F2 F3 F4

I

O

LCDDISPLAY

FUNCTIONKEYS

ACTIONKEYS

ALPHANUMERICKEYS

SHIFTKEYS

35560012

Figure 3-4. HART Communicator OperatorInterface


July 2001


Model OPM 2001

the model name of the connected deviceand its tag. In addition, the bottom line ofeach menu is reserved for the dynamic la-bels for each software-defined function key(F1 through F4) directly below the display.

b. Function Keys (F1 through F4)The function of each key varies dependingon the name that displays above it in thelast line of the LCD display. Table 3-1 pro-vides the location and purpose of each key.

Table 3-1. Function Keys

F1 F2 F3 F4HELP

Accesses on-line helpON/OFF

Activates or deactivatesa bit-enumerated binaryvariable

ABORTTerminates current taskwithout saving configura-tion data

OKAcknowledges informa-tion on the screen

RETRYTries to re-establishcommunication

DELDeletes current character

ESCLeaves a value un-changed

ENTERAccepts user-entereddata

EXITLeaves the current menu

SENDSends configuration datato the device

QUITTerminates a sessionbecause of a communi-cation error

EXITLeaves the current menu

YESAnswer to yes/no ques-tion

PGUPMoves up one helpscreen

PGDNMoves down one helpscreen

NOAnswer to yes/no ques-tion

ALLIncludes current Hot Keyitem on Hot Key Menu forall devices

PREVGoes to a previous mes-sage in a list of mes-sages

NEXTGoes to the next mes-sage in a list of mes-sages

ONEIncludes Hot Key item forone device

NEXTGoes to the next variablein off-line edit

SAVESaves information tomemory module or datapack

HOMEGoes to the top menu inthe device description

FILTROpens customizationmenu to sort configura-tions

MARKToggles marked configu-ration variables forsending to a field device

BACKGoes back to the menufrom which HOME waspressed

XPANDOpens detailed configu-ration information

EDITEdits a variable value

CMPRSCloses detailed configu-ration information

ADDAdds current item to HotKey Menu



Model OPM 2001

Table 3-2. Action Keys

Key Function

I/O Turns the HART Communicator ON and OFF.

! The up arrow key moves the cursor up through a menu or list of options. An up arrow symbolnext to a menu option on the display indicates that you can scroll upward for more options.

⟩⟩⟩ The hot key provides fast access to your most frequently used tasks. Refer to the HART Com-municator manual for more information.

" The left arrow key moves the cursor to the left in an editable field or returns to a previousmenu. A left arrow symbol in the top right-hand corner of the display indicates that you can re-turn to a previous menu.

# The down arrow key moves the cursor down through a menu or list of options. A down arrowsymbol next to a menu option on the display indicates that you can scroll downward for moreoptions.

$ The right arrow key moves the cursor to the right in an editable field or selects a menu option.A right arrow symbol next to a highlighted menu option indicates the option contains moreselections.

c. Action Keys

The action keys are located just below thefunction keys on the HART Communicator.Table 3-2 describes the function of eachkey.

d. Alphanumeric and Shift Keys

The alphanumeric keys (Figure 3-4) can beused to select menu options or enter data.

If you press only the alphanumeric keywithin an edit menu, only the bold numericcharacter in the center of the key isselected.

To select the other characters on the key,first press and release the appropriate shiftkey and then press the alphanumeric key.For example, to select the letter K, firstpress the second shift key and then pressthe K key.

3-5 USING THE HART INTERFACE

Once the HART Communicator is connected tothe OPM 2001 system, turn on the HARTCommunicator using the I/O key. The firstscreen that displays is the online menu (Figure3-5) which has the following menu options: DE-VICE SETUP, PV, SV, TV, and MODE.

35560013

!"

Figure 3-5. On-line Menu


July 2001


Model OPM 2001

NOTEAs you set up your OPM 2001 system,record all of your settings for refer-ence on the worksheet provided inAppendix C.

a. DEVICE SETUP

This menu item expands into the menu treeshown in Figure 3-10 at the end of this sec-tion. It contains all of the displays and pro-cedures used to monitor and control theOPM 2001 system. Refer to paragraphs 3-6through 3-10 for more information.

To select a menu option within the DEVICESETUP menu structure, either press theright arrow action key or use the alphanu-meric keypad and press the number thatcorresponds with the menu option.

b. PV, SV, and TV

PV, SV, and TV are standard HART termsfor primary value, secondary value, and ter-tiary value. These menu items are display-only variables that display critical, up-to-date device information such as opacity,stack temperature, transmittance, etc. Theinformation monitored by these three vari-ables are also connected to the three ana-log outputs.

c. MODE

The mode continuously displays systemstatus. The system can be in one of tenmodes as described in Table 3-3. Thesemode indications aid in troubleshooting thesystem. Refer to Section 8 for moreinformation.

3-6 PROCESS VARIABLES MENU

This menu displays the variables critical to theOPM 2001 process, such as the voltages pro-duced by the different light paths in the trans-ceiver and retroreflector. Also, it gives you theopportunity to specify three variables (PV, SV,and TV) to monitor on the online menu.

Table 3-3. System Status Modes

Mode Description

RUN Normal operating mode.

CAL An offline calibration is in prog-ress.

OPTICS CHK An optics check is in progress.

FLTR CHK A filter check is in progress.

ZSP CHK A zero/span check is in prog-ress.

CALF The last calibration failed.

COMF A communication failure existsbetween the transceiver and theintelligent electronics.

SYSFLT A system fault condition exists,such as a lamp failure, high lampvoltage reading, or blower fail-ure.

CALF&SYSFLT The last calibration failed and asystem fault exists.

FIXED MA A trim DAC procedure or looptest is in progress.

To access the PROCESS VARIABLES menu,select the DEVICE SETUP menu item from theonline menu and select PROCESS VARI-ABLES. Four menu options are available: FLDDEVICE VOLTS, OUTPUT VARIABLES, VARI-ABLE MAPPING, and VARIABLE RE-MAP.

a. FLD DEVICE VOLTS

This submenu displays the current values offour voltages produced by the different lightpaths taken in each measurement cycle. Italso displays the stack temperature and thevoltage needed to calculate the stack tem-perature. To access the FLD DEVICEVOLTS submenu, select FLD DEVICEVOLTS from the PROCESS VARIABLESmenu. The available menu items are ex-plained in Table 3-4.



Model OPM 2001

Table 3-4. FLD DEVICE VOLTS Submenu

Menu Item Typical Value Description

VSTACK(read-only)

1.839 V Voltage produced when a generated light beam is sent across thestack and reflected back to the transceiver by the retroreflector.

VLAMP(read-only)

3.848 V Voltage produced when a generated light beam is reflected withinthe transceiver; used to compensate for the effects of an agingbulb, other aging components, and power fluctuations.

VAMB(read-only)

0.805 V Voltage produced from the ambient light coming from the stack.

VDARK(read-only)

0.211 V Voltage produced when the voltage detector is blocked from thelight beam and ambient light; used to compensate for any internallight leakage within the transceiver.

Stack Temperature N/A Menu item that further sub-divides into Vad590 and Temp.

Vad590(read-only)

3.000 V Voltage produced from the temperature of the optical assembly inthe transceiver; used to calculate the stack temperature.

Temp(read-only)

27°C Stack temperature (in °C). The stack temperature is calculated us-ing the following equation:

(Vad590 × 100) - 273 = Stack Temperature

The light paths are controlled by the LiquidCrystal Windows (LCWs) shown in Figure3-6. The LCWs are transparent when ONand translucent when OFF. In the translu-cent state, light is scattered and effectivelyblocked. Table 3-5 shows the LCW state foreach measured voltage. LCW 2 has fivesectors that can be individually controlledduring the zero and span checks. Seeparagraph 3-9b. During normal operation,all of the sectors are turned ON and OFF atthe proper time.

Table 3-5. LCW States

VOLTAGE LCW 1LCW 2

(Sector 5)LCW 2

(Sectors 1 - 4)

VSTACK ON ON OFF

VLAMP ON OFF ON

VAMB OFF ON OFF

VDARK OFF OFF OFF

LCW 1LCW 2

BEAMSPLITTER

LAMP

DETECTOR

35560014

OBJECTIVELENS

Figure 3-6. LCW Locations


July 2001


Model OPM 2001

b. OUTPUT VARIABLES

This submenu is used to identify the threevariables (PV, SV, and TV) that define theanalog outputs (AO1, AO2, and AO3). Toaccess this display, select OUTPUT

VARIABLES from the PROCESS VARI-ABLES menu. Selecting a variable on thissubmenu accesses a display listing the fourparameters that define each variable as ex-plained in Table 3-6.

Table 3-6. OUTPUT VARIABLES Submenu

Menu Item DescriptionDefaultSetting

PV Output Vars Displays the four parameters that define PV (analog output 1). N/A

PV is (read-only) Identifies the type of output variable. PV can represent opacity,transmittance, optical density, extinction, or dust concentration.

Opacity

PV Value (read-only) Displays the PV value in the appropriate units for the variable se-lected.

N/A

% Range (read-only) Displays the upper range value that corresponds to the full-scaleanalog output as a percentage of range. This variable is used toscale the analog output. For example, if % RANGE is set to 25%,any variable value greater than or equal to 25% of full range willforce the analog output to be 20 mA. Refer to paragraph 3-8b formore information.

N/A

PV AO (read-only) Displays the analog output value in milliamps. N/A

SV Output Vars(read-only)

Displays the four parameters that define SV (analog output 2). SVcan represent opacity, transmittance, optical density, extinction,dust concentration, temperature, lx/lt, or one of the 12 averagesdetailed in paragraph 3-9c.

Transmittance

TV Output Vars(read-only)

Displays the four parameters that define TV (analog output 3). TVcan represent opacity, transmittance, optical density, extinction,dust concentration, temperature, lx/lt, or one of the 12 averagesdetailed in paragraph 3-9c.

Temperature



Model OPM 2001

c. VARIABLE MAPPING

This display-only menu item identifies thethree variables selected to represent PV,SV, and TV. To access this display, selectVARIABLE MAPPING from the PROCESSVARIABLES menu. To exit the display,press Exit.

d. VARIABLE RE-MAP

This procedure allows you to select thethree variables that represent PV, SV, andTV.

Use the following procedure to change thePV, SV, and TV output variables.

1. Select VARIABLE RE-MAP from thePROCESS VARIABLES menu.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming the VARIABLE RE-MAP pro-cedure may result in undesiredequipment performance.

2. Next, a Pressing OK will change de-vice output. Put loop in manual mes-sage appears. Remove the OPM 2001from any automatic control loops toavoid undesirable equipment perform-ance and press OK.

NOTEThe MORE option in the scrollable listindicates that additional selections areavailable on the next screen. However,if you select the MORE option, youcannot return to the selections on theprevious screen.

3. The next screen prompts you to selecta PV variable. Select one of the vari-ables from the scrollable list and pressEnter.

4. The following screen prompts you toselect an SV variable. Select one of thevariables from the scrollable list andpress Enter.

5. The next screen prompts you to selecta TV variable. Select one of the vari-ables from the scrollable list and pressEnter.

6. Next, a Return control loop to auto-matic control note appears. Return theOPM 2001 to the automatic controlloops previously removed and pressEnter.

7. Access the VARIABLE MAPPING dis-play to verify if the variables reflect thelatest changes.

3-7 DIAG/SERVICE MENU

This menu is used to perform diagnostics totroubleshoot and service the OPM 2001. To ac-cess the DIAG/SERVICE menu, select the DE-VICE SETUP menu item from the online menuand select DIAG/SERVICE. Seven submenusare available: STATUS, OFFLINE CAL, REF.VOLTAGES, TRIM DAC, LOOP TEST, CHECKOPTICS, and FLTR CHK.

a. STATUS

The menu items in the STATUS submenuindicate current instrument status, alarmstatus, and possible equipment or commu-nication failures. Whenever the status modeon the online menu indicates a CALF,COMF, SYSFLT, or CALF&SYSFLT mode,access the STATUS submenu to display thecurrent instrument status and alarmstatuses that may indicate a possibleequipment or communication failure. All ofthe menu items displayed will be either ONor OFF.

To access the STATUS submenu, selectSTATUS from the DIAG/SERVICE menu.

Refer to Section 8 for more information onhow the STATUS menu items are used totroubleshoot the OPM 2001.


July 2001


Model OPM 2001

b. OFFLINE CALThe OFFLINE CAL menu item provides aprocedure to perform an offline calibration.The OPM 2001 is calibrated at the factoryper customer data specifications. Only re-calibrate the unit in a clean laboratory area,or on a clear stack while using the zero jigoption. The resulting voltages are stored inthe non-volatile memory of the softwarechip on the stack LON board in thetransceiver.

To calibrate the unit, use the followingprocedure.

1. If calibrating while the unit is installedon the stack using a zero jig, go to step2. If calibrating the unit in a clean labo-ratory, use the following procedure:

(a) Remove optical assembly (1, Fig-ure 5-1) from the transceiver mod-ule per paragraph 7-3a1.

(b) Remove the retroreflector weatherhousing, turn off power to the retro-reflector blower, and remove theretroreflector body (Figure 4-1). In-stall the weather housing on theretroreflector module.

(c) Turn off power to the intelligentelectronics (Figure 6-1 or Figure6-5 as appropriate). Tag and re-move all cables and wires from theintelligent electronics and removethe unit from its mounting location.

(d) Move optical assembly, retrore-flector body, and intelligent elec-tronics to a clean laboratory.

(e) Set up the transceiver and retro-reflector in a zero opacity location.Ensure the test setup has thesame flange-to-flange distance (lf)as on the stack and make sure thetransceiver and retroreflector areproperly aligned. Refer to Section4 for alignment information if nec-essary.

(f) Connect the LON test cable tocommunications cable (3, Figure5-1) and the LON connector on theintelligent electronics.

(g) Connect the transceiver power testcable to power cable (2) and asuitable voltage source.

(h) Connect the HART Communicatorto the intelligent electronics andturn on the communicator.

(i) To access the FLD DEVICE VOLTSsubmenu, select DEVICE SETUPfrom the online menu and selectPROCESS VARIABLES. Next, se-lect FLD DEVICE VOLTS. Examinethe VSTACK and VLAMP variables.

(j) If the VSTACK or VLAMP variable re-quires adjustment, remove electron-ics housing (14, Figure 5-2) andrefer to paragraph 7-3d to adjust thegain or iris. The VSTACK value shouldbe between 1.5 and 2.0 V. For bestperformance, adjust VSTACK to 2.0±0.1 V. The VLAMP value should bebetween 3.0 and 4.0 V. For bestperformance, adjust VLAMP to 4.0±0.1 V.

(k) Install electronics housing (14).

2. If not attached, connect the HARTCommunicator at the stack terminationboard or the intelligent electronics perparagraph 3-2 and turn on thecommunicator.

3. If using a zero jig for this offline cali-bration, insert the jig per paragraphs3-7g2(c) through (e).

4. Select OFFLINE CAL from the DIAG/SERVICE menu.

5. The first screen prompts you to pressthe pushbutton light to begin the cali-bration. Press the CAL/CHECK backlitbutton (Figure 3-7) on the front mount-ing plate of the transceiver, and thesystem automatically begins to meas-ure 0% opacity and record 0% opacityreference volts.

6. The next screen informs you to waitwhile the system performs a 0% cali-bration. Once 0% calibration is com-plete, the system instructs you to turnthe corner cube around and press thepushbutton light to begin 100% calibra-tion. The back of the corner cube is a



Model OPM 2001

black reflector that simulates 100%opacity. If the zero jig is in use, insertthe black paddle that shipped with thezero jig instead of using the back of thecorner cube. Press the CAL/CHECKbacklit pushbutton on the front mount-ing panel of the transceiver.

7. The next screen informs you to waitwhile the system performs a 100%calibration. When 100% calibration iscomplete, the system instructs you toturn the corner cube back around andpress the pushbutton light to continue.If the zero jig is in use, remove theblack paddle from the zero jig insteadof turning the corner cube around.Press the CAL/CHECK backlit push-button on the front mounting panel ofthe transceiver.

8. Next, the screen displays the current PVvalue and Optical Correction Factor(OCRF) and gives you three options:REFRESH, CHANGE OCRF, and ENDCALIBRATION.

The OCRF provides a correction factorfor an offline calibration. Normally, thisvalue should be left at 0.00. If certifiedneutral density filters (NDFs) are avail-able, they can be inserted into the lightpath to verify the calibration. TheOCRF can then be adjusted to forcethe unit to better match the filter val-ues. The OCRF is a percent of readingcorrection and is limited to ±10%. Thisfactor normally is not required becausethe OPM 2001 is capable of measuringwell within 2% opacity.

The following example demonstratesthe use of the OCRF.

NOTEIn these examples, lx/lt equals 1. If lx/Itdoes not equal 1, correct the opacityreading for lx/lt. Refer to paragraph3-7g4. Then, adjust the OCRF ifnecessary.

The certified values for three differentNDFs are the following:

NDF #1 = 8.1%NDF #2 = 20.5%NDF #3 = 37.9%

During an offline calibration of the OPM2001, the three NDFs have the follow-ing opacity readings while the OCRFequals 0:

NDF #1 = 8.5%NDF #2 = 22.5%NDF #3 = 41.0%

Since the opacity readings of the threeNDFs are not the same as their certi-fied values, the OCRF should bechanged to make the opacity readingmore accurate. When the OCRF ischanged to 2, the three NDFs have thefollowing opacity readings:

NDF #1 = 8.65%NDF #2 = 22.9%NDF #3 = 41.6%

When the OCRF is changed to -10, thethree NDFs have the following opacityreadings:

NDF #1 = 7.7%NDF #2 = 20.5%NDF #3 = 37.8%

In this example, changing the OCRFvalue to -10 is the best setting becauseit changes the opacity readings of allthree of the NDFs closest to theircertified valuesNDFs 2 and 3 inparticular.

9. To change the OCRF, select theCHANGE OCRF menu item, changethe OCRF to a value between -10.0and +10.0, and press Enter.

10. Select the REFRESH menu item toupdate the PV and OCRF values.


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Model OPM 2001

11. Select END CALIBRATION to return tothe DIAG/SERVICE menu.

12. Remove the zero jig if it is in use.

c. REF. VOLTAGES

REF. VOLTAGES submenu displays volt-ages that were measured during the lastoffline calibration at 0% opacity and at

100% opacity. It also displays the date andtime of the last offline calibration. The cur-rent voltages can be compared to thereference values to determine how muchthey have changed since the last calibra-tion. The opacity monitor formulas compen-sate for changes in ambient light and thelamp intensity. Table 3-7 identifies the ref-erence voltages and provides typical valuesfor each. For definitions of the voltage val-ues refer to Table 3-4.

Table 3-7. REF. VOLTAGES Submenu

Menu ItemTypicalValues Description

CalDate (read-only) 04/09/01 Date of the last calibration (DD/MM/YY). This parameter automati-cally updates upon calibration.

CalTime (read-only) 02:00 Time of day of the last calibration (HH:MM). This parameter auto-matically updates upon calibration.

VSTACK0 (read-only) 1.887 Voltage value at 0% opacity.

VLAMP0 (read-only) 3.891

VAMB0 (read-only) 0.805

VDARK0 (read-only) 0.211

VSTACK1 (read-only) 0.842 Voltage value at 100% opacity.

VLAMP1 (read-only) 3.822

VAMB1 (read-only) 0.428

VDARK1 (read-only) 0.204

OCRF (read-only) 0.000 Correction factor for an offline calibration.



Model OPM 2001

d. TRIM DACThe TRIM DAC procedure is used to cali-brate the PV (AO1) 4-20 mA signal loop byreferencing a high and low count. The PVneeds to be trimmed because it uses anintegrated circuit to control AO1 that is dif-ferent than the circuits in SV and TV. Thedigital information needed to set the analogoutput correctly varies between integratedcircuits. Therefore, to make the integratedcircuit accurate, the software needs thedigital information collected by trimming theanalog output. This diagnostic procedurehelps to maintain optimum accuracy and ef-ficiency when communicating with otherdevices.

In the TRIM DAC procedure, the OPM 2001is placed in the fixed mA mode in which thedigital-to-analog converter outputs a speci-fied milliamp signal, such as 4 mA. By at-taching a reference meter to the analogoutput connections, you can view what theinstrument is actually outputting, which maynot be 4 mA. The TRIM DAC procedure usesthe reference meter value to calibrate thedigital-to-analog converter to ensure it out-puts 4 mA. Use the following procedure tocalibrate the analog outputs:

1. To access the TRIM DAC procedure,select TRIM DAC from theDIAG/SERVICE menu.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming the TRIM DAC procedure mayresult in undesired equipmentperformance.

2. Next, a Loop should be removed fromautomatic control warning appears.Remove the OPM 2001 from anyautomatic control loops to avoid unde-sirable equipment performance andpress Enter.

3. The next screen directs you to connecta reference meter. Connect an amme-ter to the analog output connections(Figure 2-10 or Figure 2-11 as appro-priate) on the intelligent electronics andpress Enter.

4. Next, the screen prompts you to enterthe meter value. Observe the valuedisplayed on the reference meter, enterthat value, and press Enter.

5. Next, the screen prompts you to enterthe meter value. Observe the valuedisplayed on the reference meter, enterthat value, and press Enter.

6. When the Returning fld device tooriginal output message displays, re-move the reference meter from theanalog output connections and pressEnter.

7. Next, a Loop may be returned toautomatic control note appears. Re-turn the OPM 2001 to the automaticcontrol loops previously removed andpress Enter. If you were to repeat theTRIM DAC procedure, the values thatdisplay on the reference meter willmatch the output of the digital-to-analog converter.

e. LOOP TESTThe loop test is a diagnostic procedure thatallows you to apply a specific current to the4-20 signal loop to verify that the analogoutput is connected correctly. To accessthis submenu, select LOOP TEST from theDIAG/SERVICE menu.

1. To verify the current in analog output 1,select LOOP TEST PV from the LOOPTEST submenu.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming a loop test may result in un-desired equipment performance.

2. Next, a Loop should be removed fromautomatic control warning appears.Remove the OPM 2001 from anyautomatic control loops to avoid unde-sirable equipment performance. At thistime, also install a reference meter toanalog output 1 that will register thesignal current. To continue the proce-dure, press Enter.


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Model OPM 2001

3. The next screen prompts you either toselect a current or to end the test.Choose 4 mA, 20 mA, or OTHER,which gives you the opportunity to en-ter a different value.

4. Once you make your selection, checkthe reference meter. If the referencemeter value does not match the se-lected value, you must check yourconnections. If the values match,analog output 1 is connectedcorrectly.

5. Select END to leave the LOOP TESTprocedure.

6. Next, a Loop may be returned toautomatic control note appears. Re-turn the OPM 2001 to the automaticcontrol loops previously removed, dis-connect the reference meter, and pressEnter.

7. To verify the analog output 2 or 3, re-peat steps 1 through 6 for LOOP TESTSV or LOOP TEST TV, respectively.

f. CHECK OPTICSRefer to Section 4 for the complete CHECKOPTICS procedure.

g. FLTR CHKThe menu items in the FLTR CHK submenuare used to verify the calibration validity ofthe OPM 2001 using a zero jig and neutraldensity filters (NDFs). A set of three differ-ent NDFs are used multiple times to complywith the EPA Filter Check Method 203Audit. Typically, this procedure takes lessthan one hour. NDFs placed in the zero jigwill display NDF values corrected for thepathlength correction ratio (OPLR)referred to as the lx/lt ratio in the OPM2001. The values will be in the units config-ured for PV. These measurements arestored by the OPM 2001 and recorded us-ing a data recorder connected to analogoutput 1. To access this submenu, select

Table 3-8. FLTR CHK Submenu

Menu Item Description

Filter Check(method)

Provides the procedure to checkthe NDFs to comply with theEPA Filter Check Method 203Audit.

Fltr Chk Values(method)

Provides the procedure to dis-play each neutral density filtervalue, in terms of PV, by se-lecting the filter number. It alsodisplays time (HH:MM) thevalue was taken.

Erase Fltr Values(method)

Provides the procedure to erasetest filter data currently storedby the OPM 2001. The old filterdata is usually erased beforestarting a new filter check.

FLTR CHK from the DIAG/SERVICE menu.Refer to Table 3-8 for descriptions of theavailable menu items.

1. Use the following procedure to erasetest filter data currently stored by theOPM 2001:

NOTEIf the stored filter values are erasedbefore starting the FILTER CHECKprocedure, the procedure will begin atfilter 1. If the stored filter values arenot erased before starting the FILTERCHECK procedure, the procedure willbegin where it previously ended.

(a) Select ERASE FLTR VALUESfrom the FLTR CHK submenu.

(b) Next, an About to erase filter val-ues message appears. Press En-ter to clear all values of previousfilter checks or press Abort to exitfrom the screen without erasing thevalues.



Model OPM 2001

2. Perform the filter check procedure asfollows:

(a) Select FILTER CHECK from theFLTR CHK submenu.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming the FILTER CHK proceduremay result in undesired equipmentperformance.

(b) Next, a Loop should be removedfrom automatic control warningappears. Remove the OPM 2001from any automatic control loops toavoid undesirable equipment per-formance and press Enter.

(c) The next screen displays anAbout to begin filter check mes-sage. At this time, remove the win-dow access plate from thetransceiver optical assembly (Fig-ure 3-7).

Figure 3-7. Zero Jig and EPA Filter Placement


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Model OPM 2001

NOTEA zero jig is specific to the transceiverto which it has been calibrated. Checkthat the serial number of the zero jig isthe same as the serial number of thetransceiver.The zero jig requires periodic calibra-tion (typically once per year). Refer toparagraph 7-4 for the zero jig calibra-tion procedure.

(d) Remove the keepers from the zerojig magnets and place the zero jigthrough the window cleaning area.Slide the jig on the window flangeand onto the locating pin.

(e) Slightly rotate the jig back and forthuntil the 2 in. (50.8 mm) diameterraised section falls into place. Thelocator pin and the two permanentmagnets hold the jig in position.

(f) Insert neutral density filter 1.

(g) Press Enter on the HARTCommunicator.

(h) The next screen prompts you topress the pushbutton light to beginreading filter 1. Press theCAL/CHECK backlit button on thefront mounting plate of the trans-ceiver.

(i) The following screen informs youto please wait (approximately fiveseconds) while the system isreading the filter.

(j) At the prompt to begin reading filter2, remove filter 1, and then insertfilter 2.

(k) Repeat steps (g) through (j) for theremaining filters.

(l) If you do not wish to check all 30filters, press Abort to exit the FIL-TER CHK procedure.

(m) At this time, remove the neutraldensity filter and zero jig from thetransceiver (Figure 3-7).

The zero jig is a sensitive, calibratedinstrument. Store the jig in its protec-tive case when not in use. Failure toproperly store the jig can lead to dam-age or an out-of-calibration condition.

(n) Install the keepers on the zero jigmagnets and return the jig to itsprotective case.

(o) Install the window access plate.

(p) When the Loop may be returnedto automatic control note appears,return the OPM 2001 to the auto-matic control loops previously re-moved and press Enter.

3. Use the following procedure to view thefilter check values:

(a) Select FLTR CHK VALUES fromthe FLTR CHECK submenu.

(b) The next screen prompts you toselect a filter. Enter the number ofthe filter (1 through 30) you wish toview and press Enter.

(c) The following screen displays thefilter number; the filter value, interms of PV; and the time the filterwas checked. To view another fil-ter, select the NEW FILTER option.To exit the procedure, select EXIT.

4. The OPM 2001 adjusts all readings forthe lx/lt ratio, including those taken withan NDF. The NDF-certified opacity val-ues are based on an lx/lt ratio of 1.0. Ifthe lx/lt ratio at your site is not equal to1.0, an adjustment must be applied tothe given NDF-certified opacity valuethat will yield the correct expectedvalue for your specific site.



Model OPM 2001

To determine the correct expectedopacity value at your site, use the fol-lowing procedure:

(a) Convert the NDF-certified opacityvalue to the equivalent optical den-sity (OD) value using the table inAppendix A.

(b) Multiply the OD value by the lx/ltratio to get an expected OD value.

(c) Convert the expected OD valueback to an (expected) opacityvalue using the table in AppendixA.

The equation for the relationship is asfollows:

expected NDF OD value = certified OD value * lx/lt ratio

Example 1:lx/lt ratio = 0.8certified NDF opacity value = 36.9%certified OD value = 0.2000 (from Appendix A)expected NDF OD value = 0.2 * 0.8 = 0.16expected NDF opacity value = 30.8% (from Appendix A)




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Model OPM 2001

3-8 BASIC SETUP MENU

This menu is used to view and configure basicsystem requirements. To access the BASICSETUP menu, select the DEVICE SETUP menuitem from the online menu and select BASICSETUP. Four submenus are available: SETUPCLOCK, RANGE VALUES, LX/LT, and DEVICEINFO.

a. SETUP CLOCK

This submenu displays the real-date andreal-time and provides a procedure to resetboth. To access the SETUP CLOCK sub-menu, select SETUP CLOCK from the BA-SIC SETUP menu. The menu itemsavailable are explained in Table 3-9.

Use the following procedure to change thedate and time:

1. From the BASIC SETUP submenu,Select CLOCK SETUP.

2. The next three screens will prompt youto enter the current date in month, day,and year, respectively. After typingeach entry in the highlighted area,press Enter.

3. The next three screens will prompt youto enter the current time in hours, min-utes, and seconds, respectively. Aftertyping each entry in the highlightedarea, press Enter.

4. The system then returns to the SETUPCLOCK submenu. Verify that the read-only displays in the submenu reflectthe latest changes.

Table 3-9. SETUP CLOCK Submenu

Menu Item Typical Value Description

Date(read-only)

09/30/97 Displays the current date (in MM/DD/YY). The date ismaintained by the real-time clock chip on the HARTdaughter PC board. A battery on the board backs upthe real-time clock in the event of a power failure.

Time(read-only)

09:30:27 Displays the current time (in HH:MM:SS). The time ismaintained by the real-time clock chip on the HARTdaughter PC board. A battery on the board backs upthe real-time clock in the event of a power failure.

Clock Setup(method)

N/A Provides the procedure to reset the date and time ofthe internal clock.



Model OPM 2001

b. RANGE VALUES

The RANGE VALUES submenu allows youto set up the ranges for the user-selectedPV, SV, and TV variables (analog outputs 1,2, and 3). To access this submenu, selectRANGE VALUES from the BASIC SETUPmenu. The menu items are SELECT PVRANGE, SELECT SV RANGE, and SE-LECT TV RANGE. The menu items for thissubmenu are explained in Table 3-10.

Use the following procedure to change theURV for the PV range:

1. From the SELECT PV RANGE sub-menu, select PV RANGE SETUP.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming the URV procedure may resultin undesired equipment performance.

2. Next, a Loop should be removed fromautomatic control warning appears.Remove the OPM 2001 from anyautomatic control loops to avoid unde-sirable equipment performance andpress Enter.

3. The next screen prompts you to enter anew upper range value for analog out-put 1 (PV). Type the value in the high-lighted area and press Enter. A typicalvalue for this variable is 100.00% of theanalog output.

4. A Saving range values message dis-plays while the system updates.

5. Next, a Loop may be returned toautomatic control note appears. Re-turn the OPM 2001 to the automaticcontrol loops previously removed andpress Enter. Verify that the read-onlyURV menu item reflects the change.

6. Repeat steps 1 through 5 for the SVand TV URV values.

NOTEIf any of the three HART variables (PS,SV, or TV) have the same processvariable (i.e., opacity, transmittance,average 1, etc.), setting the URV of oneanalog output will affect the URV ofeach analog output whose corre-sponding HART variable has been as-signed the same process variable. Forexample, if SV and TV are both as-signed the process variable of opacity,then setting the URV of analog output2 (SV) to 50% will automatically set theURV of analog output 3 (TV) to 50%.

Table 3-10. PV, SV, and TV RANGE VALUES Submenu


Select PV Range Contains the following three parameters that define the PV range.

URV(read-only)

Displays the upper range value for the selected variable as a percentageof the analog output. A typical value for this variable is 100.00%. TheURV can be modified using the PV RANGE SETUP method.

LRV(read-only)

Displays the lower range value for the selected variable as a percentageof the analog output. A typical value for this variable is 0.00%. This pa-rameter cannot be modified.

PV Range Setup(method)

Provides the procedure to change the URV of the selected variable.

Select SV Range Refer to the Select PV Range menu item.

Select TV Range Refer to the Select PV Range menu item.


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c. LX/LT

lx/lt is the ratio of the inside diameter at thetop of the stack to the inside diameter of thestack where the instrument is located. SeeFigure 3-8. If the ratio is greater than 1.0,the exit opacity will be greater than theopacity at the instrument location. The OPM2001 uses this correction factor to calculatethe stack exit opacity. It is not practical tohave an lx/lt factor much greater than 2.0because the error of the instrument in-creases as lx/lt becomes greater.

The LX/LT submenu allows you to view andconfigure the lx/lt ratio. The LX/LT menuitem is a read-only display of the current lx/ltvalue. Its default setting is 1.00. This valuecan be changed using the LX/LT SETUPmenu item.

Use the following procedure to change thelx/lt variable:

1. From the LX/LT submenu, select LX/LTSETUP.

2. The next screen prompts you for thelx/lt variable. Calculate the ratio tothree decimal places by dividing the in-side diameter of the top of the stack(lx) by the inside diameter of the stackat the instrument (lt). Type the newvalue in the highlighted area and pressEnter.

Figure 3-8. lx and lt Stack Dimensions

3. A Saving Lx/Lt message displayswhile the system updates. Once thevalue is saved, the system returns tothe LX/LT submenu. Verify that theread-only Lx/Lt display reflects thechange.

d. DEVICE INFO

This submenu allows you to program de-scriptive or pertinent user information. Toaccess this submenu, select DEVICE INFOfrom the BASIC SETUP menu. The menuitems for this submenu are explained in Ta-ble 3-11.

Table 3-11. DEVICE INFO Submenu.


Dev id (read-only) Identifies the device used with the HART Communicator. The device ID also ap-pears at the top of each screen in the HART Communicator.

Descriptor (read, write) Provides a 16-character entry to convey user information.

Tag (read, write) Provides an 8-character entry to convey user information. Appears on the topline of every HART display next to the device ID.

Message (read, write) Provides a 32-character entry to convey user information.



Model OPM 2001

Use the following procedure to enter a de-scriptor, tag, or message:

1. To add descriptive information, selectDESCRIPTOR, TAG, or MESSAGEfrom the DEVICE INFO submenu. Re-fer to Table 3-11 for an explanation ofeach parameter type.

2. The next screen prompts you to enterthe descriptive information. Type theentry in the highlighted area and pressEnter.

3. The system exits to the DEVICE INFOsubmenu. Verify that the parameter youmodified reflects the latest changes.

3-9 DETAILED SETUP MENUThe DETAILED SETUP menu is used to config-ure the OPM 2001 for specific applications. Toaccess the DETAILED SETUP menu, select theDEVICE SETUP menu item from the onlinemenu and then select DETAILED SETUP. Fivesubmenus are available: RELAY CONFIG,ZERO/SPAN CHECK, AVERAGES, ALARMS,and DUST SETUP.

a. RELAY CONFIGThe RELAY CONFIG submenu allows youto configure the relays to energize uponcertain alarm or status conditions. It alsoallows you to view the currently selectedtrigger signals. To access this submenu,select RELAY CONFIG from the DETAILEDSETUP menu. The menu items in the sub-menu are explained in Table 3-12.

Table 3-12. RELAY CONFIG Submenu

Menu Item Possible Variables Description Default Setting

Relay Config(method)

N/A Provides the relay configuration procedureby selecting the variable that triggers eachrelay.

N/A

Relay 1(read-only)

OffSysflt (System Fault)Span (Span Check)Zero (Zero Check)Flt Chk (Filter Check)Alarm 1Alarm 2On

Displays the currently selected variable forrelay 1.

Alarm 1

Relay 2(read-only)

Same as Relay 1 Displays the currently selected variable forrelay 2.

Alarm 2

Relay 3(read-only)


Fltr Chk

Relay 4(read-only)


Zero Chk

Relay-5(read-only)


Span Chk

Relay-6(read-only)


Sysflt


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Model OPM 2001

NOTERelays 1 through 5 are normally open.Relay 6 is normally closed.

To change a default relay output setting,use the following procedure:

1. From the RELAY CONFIG menu, se-lect the RELAY CONFIG menu item.

2. The next screen prompts you to selecta relay or exit. Scroll through the list,select a relay, and press Enter.

3. At the next prompt, select one of thesignal variables from the scrollable listand press Enter. Note that no two re-lays can have the same trigger signal.

4. The display will then prompt you toconfigure another relay or exit the pro-cedure. To configure another relay, re-peat steps 2 through 4. When finished,press Exit to return to the RELAYCONFIG submenu. Verify that the set-tings reflect the latest changes by ac-cessing the read-only displays in thesubmenu.

b. ZERO/SPAN CHECK

The ZERO/SPAN CHECK submenu allowsyou to periodically verify the operation of theunit. Zero and span checks are required byEPA performance specification 1, section5.1.5, as repeated below:

5.1.5 Simulated Zero and Upscale Calibra-tion System. Each analyzer must include azero (or no greater than 10%) opacity andan upscale opacity value for the purpose ofperforming periodic checks of the transmis-someter calibration while on an operatingstack or duct. This calibration system willprovide, as a minimum, a system check of

the analyzer internal optics and all elec-tronic circuitry including the lamp and pho-todetector assembly.

The OPM 2001 uses a sectored LiquidCrystal Window (LCW) to simulate an in-termediate zero and upscale calibrationcheck value. The individual sectors areidentified in Figure 3-9.

The ZERO/SPAN CHECK submenu allowsyou to view and configure the zero andspan check parameters. To access thissubmenu, select ZERO/SPAN CHECK fromthe DETAILED SETUP menu. Table 3-13explains the ZERO/SPAN menu items.

The typical values displayed in Table 3-13exemplify a zero/span check that is per-formed once a day at 2:00 a.m. SPAN VALwill assume the span check value of23.45% opacity for six minutes. The zerocheck value will then be output for the nextsix minutes. If using the default relay setupdescribed in Table 3-12, relay 5 is ener-gized during the span check, and relay 4 isenergized during the zero check. This func-tion is enabled when the blower motors arerunning. Any fault condition will disable thisfunction.

Figure 3-9. Sectored LCW2



Model OPM 2001

Table 3-13. ZERO/SPAN CHECK Submenu

Menu ItemPossibleVariables

TypicalValue Description

DefaultSetting

Zero Val(read-only)

N/A 6.22% Displays the analog output value as a percent-age of opacity during the last zero check.

N/A

Zero Fltr(read, write)

S0 through S15(Refer to Table6-14 for filterdescriptions.)

S14 Displays and selects the LCW sectors that de-termine the nominal opacity value for zerocheck. To change the variable, select ZEROFLTR and follow the instructions on the screen.

S0

Span Val(read-only)

N/A 23.45% Displays the analog output value as a percent-age of opacity during the last span check.

N/A

Span Fltr(read, write)

S0 through S15(Refer to Table6-14 for filterdescriptions.)

S12 Displays and selects the LCW sectors that de-termine the nominal opacity value for spancheck. To change the variable, select SPANFLTR and follow the instructions on the screen.

S0

Period(read-only)

value within the00:00 to 24:00hour range

24:00 Indicates the length of time between check cy-cles (in HH:MM).

00:00

Start(read-only)

value within the00:00 to 24:00hour range

02:00 Indicates the time of day the check cycle willbegin (in HH:MM).

00:00

Zero Dur(read-only)

value within the00:00 to 10:00minute range

6.00 Indicates the length of the zero check cycle (inMM:SS).

00:00

Span Dur(read-only)

value within the00:00 to 10:00minute range

6:00 Indicates the length of the span check cycle (inMM:SS).

00:00

Zero/SpanConfig(method)

N/A N/A Provides the procedure to set the parametersfor the zero/span check.

N/A

The user-required span and zero check val-ues determine which sectors to select. Ta-ble 3-14 shows the on/off status of thesectors with each filter check value. All val-ues listed in Table 3-14 are nominal. Whatis important is that the span check and thezero check values remain consistent fromday to day.

To configure the zero/span check, use thefollowing procedure:

1. From the ZERO/SPAN CHECK sub-menu, select ZERO/SPAN CONFIG.

2. The following two screens will directyou to enter the zero/span period in


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Model OPM 2001

Table 3-14. LCW Sector Status

LCW SECTOR

FilterValue 1 2 3 4

NominalCapacity

NominalTransmittance

Nominal OpticalDensity/Extinction

S0 OFF OFF OFF OFF 99.9 0.1 3.000

S1 OFF OFF OFF ON 93.3 6.7 1.174

S2 OFF OFF ON OFF 86.6 13.4 0.873

S3 OFF OFF ON ON 80.0 20.0 0.699

S4 OFF ON OFF OFF 73.3 26.7 0.574

S5 OFF ON OFF ON 66.6 33.4 0.477

S6 OFF ON ON OFF 60.0 40.0 0.398

S7 OFF ON ON ON 53.3 46.7 0.331

S8 ON OFF OFF OFF 46.6 53.4 0.273

S9 ON OFF OFF ON 40.0 60.0 0.222

S10 ON OFF ON OFF 33.3 66.7 0.176

S11 ON OFF ON ON 26.6 73.4 0.134

S12 ON ON OFF OFF 20.0 80.0 0.097

S13 ON ON OFF ON 13.3 86.7 0.062

S14 ON ON ON OFF 6.6 93.4 0.030

S15 ON ON ON ON 0.0 100.0 0.000

hours and minutes, respectively. Aftertyping each entry in the highlightedarea, press Enter.

3. The next two screens will direct you toenter the zero/span start time in hoursand minutes, respectively. After typingeach entry in the highlighted area,press Enter.

4. The following two screens will promptyou to enter the zero duration in min-utes and seconds, respectively, Aftertyping each entry in the highlightedarea, press Enter.

5. The next two screens will prompt youto enter the span duration in minutesand seconds, respectively. After typing

each entry in the highlighted area,press Enter.

6. At the next screen prompt, select thezero filter from the scrollable list andpress Enter.

7. In the following screen, select the spanfilter from the scrollable list and pressEnter.

8. Next, a Writing zero/span configura-tion message appears as the systemupdates. After configuring thezero/span check, the system returns tothe ZERO/SPAN CHECK submenu.Verify that the settings reflect the latestchanges by viewing the read-only dis-plays in the submenu.



Model OPM 2001

c. AVERAGES

This submenu allows you to configure up totwo averages of opacity, transmittance, op-tical density, extinction, dust concentration,or none (no variable specified). For eachvariable, a time period is specified and theaverage is calculated from the number ofmeasurements taken during that time pe-riod. To access this submenu, select AV-ERAGES from the DETAILED SETUPmenu. Table 3-15 explains the menu itemsin the AVERAGES submenu.

To configure an average, use the followingprocedure:

1. From the AVERAGES submenu, selectthe average you want to configure.

2. The next screen prompts you to con-figure either the variable type or thetime period of the selected average.Select VAR.

3. At the prompt, select one of the vari-ables from the scrollable list and pressEnter. To exit the screen without mak-ing a selection, press Esc.

4. Next, select PER to configure the timeperiod of the selected average.

5. At the prompt, select one of the timeperiods from the scrollable list andpress Enter. To exit the screen withoutmaking a selection, press Esc.

6. To configure another average, repeatsteps 1 through 5. Once all desired av-erages are configured, press Send tosend the average configurations to theintelligent electronics.

Table 3-15. AVERAGES Submenu



DefaultSetting

Average 1Average 2(read-only)

N/A N/A Displays the current average value. Se-lecting each average displays the vari-able type and the time period of thataverage.

N/A

Avg XVariable(read-only)

NoneOpacityTransmittanceOptical DensityExtinctionDust Concentration

Opacity(for Avg 1)

Displays the type of variable specified forthe average calculation.

None

Avg XPeriod(read-only)

15 sec1 min2 min3 min4 min5 min6 min10 min12 min15 min20 min30 min60 min

6 min Displays the time period during which thevariable measurements are collected.

15 sec


July 2001


Model OPM 2001

d. ALARMS

This submenu allows the configuration oftwo alarms. Through the relay outputs, eachalarm can indicate when a variable is notwithin range. In the default system setup,

alarms 1 and 2 control relay outputs 1 and2, respectively. To access this submenu,select ALARMS from the DETAILEDSETUP menu. The nine available menuitems are explained in Table 3-16.

Table 3-16. ALARMS Submenu



DefaultSetting

Alarm Con-figuration(method)

N/A N/A Provides the procedure to change thealarm configurations.

N/A

Alarm 1Alarm 2(read-only)

OpacityTransmittanceOptical DensityExtinctionDust ConcentrationLx/LtAvg 1 through 12

Opacity Identifies the variable to monitor. None

Alarm 1 TypeAlarm 2 Type(read-only)

HighLowNone

High Identifies which end of the variable rangeto monitor. For example, if a high alarmtype is selected, the alarm will activate ifthe variable exceeds the alarm setpoint. Ifa low alarm type is selected, the alarm willactivate if the variable falls below the alarmsetpoint. Selecting none will not configurean alarm.

None

AL1 SetpointAL2 Setpoint(read-only)

XXX.XX% 100.00% Identifies the high or low limit of the vari-able, depending on the alarm type setting.

0

AL1 DeadbandAL2 Deadband(read-only)

X.XX% 1.0% Represents the value that must be sub-tracted from the setpoint before the alarmwill deactivate. For a high alarm, the vari-able will activate the alarm if its value ex-ceeds the alarm setpoint. The alarm willnot deactivate until the variable valuedrops below the alarm setpoint minus thedeadband. The deadband is designed toprevent a chattering alarm.

0



Model OPM 2001

Alarm configuration is flexible. However, thealarms are normally configured for high val-ues of opacity or opacity averages. Use thefollowing procedure to configure the alarms:

1. From the ALARMS submenu, selectALARM CONFIG.

2. The next screen prompts you to selectthe Alarm 1 setting. Select one of thevariables from the scrollable list andpress Enter.

3. The next screen prompts you to selectthe alarm 1 type. Select one of thevariables from the scrollable list andpress Enter.

4. At the alarm 1 setpoint prompt, typethe new value in the highlighted fieldand press Enter.

5. At the alarm 1 deadband prompt, typethe new value in the highlighted fieldand press Enter.

6. Repeat steps 2 through 5 to configurealarm 2.

7. After configuring both alarms, the sys-tem returns to the ALARMS submenu.Verify that the settings reflect the latestchanges.

e. DUST SETUPThe menu items in this submenu enable theunit for dust concentration measurements.To access this submenu, select DUSTSETUP from the DETAILED SETUP menu.The five available menu items are explainedin Table 3-17.

After iso-kinetic sampling has occurred anddata has been plotted for the c and k val-ues, c and k can be entered as constants.

Use the following procedure to enter thevalues needed to relate extinction readingsto the dust concentration (DC).

1. From the DUST SETUP submenu, se-lect DUST CONFIGURATION.

2. The next screen prompts you to enterthe dust C constant. Type the newvalue in the highlighted field and pressEnter.

3. The next screen prompts you to enterthe dust K constant. Type the newvalue in the highlighted field and pressEnter.

4. A Writing dust constants messageappears as the system updates. Then,the system returns to the DUSTSETUP submenu. Verify that the con-stants and date and time reflect thelatest changes.

Table 3-17. DUST SETUP Submenu

Menu ItemTypicalValue Description

DefaultSetting

Dust C (read-only) 0.400 Offset constant determined by gravimetric sampling. 0

Dust K (read-only) 66.800 Gain constant determined by gravimetric sampling. 0

Date (read-only) 09/30/97 Records when the dust constants were last changed(MM/DD/YY). The system automatically updates thisparameter.

N/A

Time (read-only) 14:32 Records when the dust constants were last changed(HH:MM). The system automatically updates this pa-rameter.

N/A

Dust Configuration(method)

N/A Provides the procedure to change the dust constants. N/A


July 2001


Model OPM 2001

3-10 REVIEW MENU

The REVIEW menu summarizes the revisioninformation for both the IG-1 software and thestack software and displays the OPM 2001system serial number. To access this menu,select the DEVICE SETUP from the onlinemenu and select REVIEW. The three availablesubmenus are explained in Table 3-18.

3-11 HART COMMUNICATOR MENU TREEFOR OPM 2001

The HART menu tree shown in Figure 3-10identifies all of the displays and proceduresused to monitor and control the OPM 2001system.

The first column in Figure 3-10 represents theonline menu. From that menu, only the DEVICESETUP selection subdivides into more specificmenu options, which consist of methods and/orinformational displays. A method is a procedurethat you can use to perform a specific task. If amethod is not associated with a menu option,the option will be a read-only or read, write (ed-itable) display.

To select a menu or menu option, either pressthe right arrow action key or use the alphanu-meric keypad and press the number shown onthe display that corresponds to the menu option.For further information about a specific menuoption, refer to paragraphs 3-6 through 3-10.

Table 3-18. REVIEW Menu

Submenu Description

IG-1 S/W Version(read-only)

Identifies the revision level and release date of the IG-1 soft-ware. The revision date includes the year, month, day, hour, andminute.

Stack S/W Version(read-only)

Identifies the revision level and release date of the stack soft-ware. The release date includes the year, month, day, hour, andminute.

Serial Numbers(read-only)

Displays the serial number of the OPM 2001 system.



Model OPM 2001

VstackVlampVambVdark

STACKTEMPERATURE

FLD DEVICEVOLTS

PV isPV value% rngePV AO

Vad590Temp

SV isSV value% rngeSV AO

PROCESSVARIABLES

DIAG/SERVICE

SV OUTPUTVARS

PV isTV isSV is

Variable re-mapmethod

LON COM StatusAO1 DAC Trim

Heater StatusPR SW #1 StatusLP Button StatusPR SW #2 StatusVlamp too HighDIG IN Status

AO1AO2AO3

AO1AO2AO3

Relay 1Relay 2Relay 3Relay 4Relay 5Relay 6

Blower FailureChk Optics ModeTCVR Cal StatusDtcr V too HighLamp Status

Offline Calmethod

Trim DACmethod

Loop Test PVmethod

Loop Test SVmethod

Loop Test PVmethod

LOOP TEST PV

LOOP TEST SV

LOOP TEST TV

TV OUTPUTVARS

PV OUTPUTVARS

OUTPUTVARIABLES

TV isTV value% rngeTV AO

VARIABLEMAPPING

VARIABLERE-MAP

STATUS

OFFLINE CAL

TRIM DAC

LOOP TEST

CalDateCalTimeVstack0Vlamp0Vamb0Vdark0Vstack1Vlamp1Vamb1Vdark1OCRF

REF.VOLTAGES

DEVICE SETUP

PV

SV

TV

MODE

35560019(CONTINUED ON

SHEET 2)

STATUSGROUP 0

STATUSGROUP 1

STATUSGROUP 2

STATUSGROUP 3

AO SATURATED

AO FIXED

(CONTINUED ONSHEET 2)

Figure 3-10. HART Menu Tree for the OPM 2001 (Sheet 1 of 3)


July 2001


Model OPM 2001




Model OPM 2001



July 2001


Model OPM 2001

SECTION 4ALIGNMENT

4-1 OPTICAL ALIGNMENT

Thermal deformation of the stack orduct can affect the accuracy of thealignment. To reduce the effects ofthermal deformation, ensure the wallof the stack or duct is stabilized at thenormal operating temperature prior toperforming the final alignmentprocedure.

Stack gases can cause serious dam-age to the opacity monitor. To preventdamage to the unit, ensure purge air ison prior to opening the air lens sealplates. Ensure the seal plates areclosed whenever the purge air bloweris not running.

a. Turn on power to the transceiver and retro-reflector.

b. Run the process long enough to stabilizethe stack walls at normal operating tem-perature. The stack walls must be at thesame temperature during final alignment asduring the operation since thermal distortionof the walls can affect alignment.

c. Enter the check optics mode as follows:

1. Attach the HART Communicator andturn on the device. Refer to paragraph3-2 for HART Communicator installa-tion information.

2. From the online menu, select DEVICESETUP.

3. Next, select DIAG/SERVICE from theDEVICE SETUP menu.

4. From the DIAG/SERVICE submenu,select CHECK OPTICS.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming the CHECK OPTICS proceduremay result in undesired equipmentperformance.

5. A Loop should be removed fromautomatic control warning appears.Remove the OPM 2001 from anyautomatic control loops and press OKto continue. Then, an About to begincheck optics status message brieflydisplays.

6. In the next screen, the system promptsyou to select the LCW state. Select theVSTACK option. The present VSTACKvalue will display. Proceed to the stack.A steady beam of light should be leav-ing the transceiver.

d. At the stack, use a screwdriver to pry openthe latches on the weatherproof housingsand remove the weather housings from thetransceiver and retroreflector.

e. Verify that each purge air blower is runningproperly.



Model OPM 2001

END CAPAND CORNER

CUBE ASSEMBLY

ALIGNMENTNUT (4)

SEAL PLATE

RETROREFLECTORBODY

6 IN.OPTICAL

EXTENSIONTUBE

OPTICALALIGNMENT

SIGHT

VIEWEND CAP

INSTALLED

A

35560036

Figure 4-1. Optical Alignment

f. Push down the seal plates on both thetransceiver and retroreflector to open thepurge air path to the flue, but do not removethe air lens seal plates (Figure 4-1).

g. Align the transceiver as follows:

1. Remove the end cap and corner cubeassembly from the retroreflector body.

2. Attach the optical alignment sight(without the extension tube) to the ret-roreflector body.

NOTEThree concentric areas are visiblethrough the alignment sight. Longerpathlengths use the larger diametercircles.


July 2001


Model OPM 2001

AAB

C10-20 FT

(3.05-6.1 M)

3-10 FT(0.915-3.05 M)

20-26 FT(6.1-7.9 M)

THE FIGURE ILLUSTRATES TOLERANCE AREAS FOR THREEPATHLENGTH RANGES. THE THREE EXAMPLE READINGS(FROM THREE DIFFERENT ALIGNMENTS) ARE AS FOLLOWS:A - WITHIN ±2% OPACITY FOR ALL PATHLENGTHS.B - WITHIN ±2% OPACITY FOR PATHLENGTHS 10 FT ( 3.05 M),

BUT OUT OF ALIGNMENT FOR PATHLENGTHS <10 FT(<3.05 M).

C - WITHIN ±2% OPACITY FOR 20 TO 26 FT (6.1 TO 7.9 M)PATHLENGTHS, BUT OUT OF ALIGNMENT FOR SHORTERLENGTHS.

≥ ≥

35560010

2.00 IN.(50.8 MM)DIA REF.

Figure 4-2. View of Crosshairs andTolerance Areas in Optical Alignment Sight

3. Observe the crosshair image projectedby the transceiver onto the alignmentsight. Note that three concentric areasprovide tolerance definition for threedifferent pathlength ranges (Figure4-2).

4. Refer to Figure 4-2. If the crosshair in-tersection is within the concentric areafor the given pathlengths, the unit isaligned within ±2% opacity.

h. If the crosshair intersection is not in thecenter of the circles, adjust the ball joint inthe transceiver module using the fouralignment nuts (Figure 4-1).

i. When alignment is complete, all four align-ment nuts should be tight.

j. Align the retroreflector as follows:

1. Remove the alignment sight at the ret-roreflector.

2. Attach the 6 in. extension tube andalignment sight to the retroreflector(Figure 4-1). The extension tube is re-quired to square the retroreflector tothe projected light beam.

3. Look directly through the alignmentsight and check for a centered beam oflight from the transceiver.

4. Use the alignment nuts on the retrore-flectors air window to center the beamof light onto the frosted field of thealignment sight. Carefully tighten thenuts while maintaining alignment.

5. Recheck the crosshairs by removing theextension tube. The crosshairs shouldremain centered. If not, readjust thetransceiver ball joint.

k. Remove the alignment sight and extensiontube from the retroreflector.

l. Install the end cap and corner cube assem-bly on the retroreflector.

m. Install the weatherproof housings over thetransceiver and retroreflector modules.

n. Using the HART Communicator, select theEXIT option to leave the check optics mode.

o. At the Return control loop to automaticcontrol message, return the OPM 2001 tothe automatic control loops previously re-moved and press Enter.

p. After waiting 30 minutes for the unit to sta-bilize, check the calibration. Recalibrate ifnecessary. Calibration can be checked byinserting the zero jig. If opacity differs from0.0% by more than ±0.5%, recalibrate perparagraph 3-7b.



Model OPM 2001

4-2 OBJECTIVE LENS ADJUSTMENT

The OPM 2001 is configured at the factory forthe users stack diameter. If readjustment isever necessary, the transceiver assembly andretroreflector body must be set in a clean envi-ronment and at the same distance apart (flange-to-flange) as when installed on the stack. Thefollowing steps are performed to focus the ob-jective lens.

Removing covers from the optical as-sembly or making optical repairs oradjustments in an unsuitable envi-ronment can affect the accuracy of theunit. Removal of the electronicshousing and optical cover, as well asall repairs and adjustments to the op-tical assembly, must be performed in aclean, dust-free environment.

a. Enter the check optics mode as follows:

1. Attach the HART Communicator to the4-20 mA signal line and turn on the de-vice. Refer to paragraph 3-2 for HARTCommunicator installation information.

2. From the online menu, select DEVICESETUP.

3. Next, select DIAG/SERVICE from theDEVICE SETUP menu.

4. From the DIAG/SERVICE submenu,select CHECK OPTICS.

Failure to remove the OPM 2001 fromautomatic control loops prior to per-forming the CHECK OPTICS proceduremay result in undesired equipmentperformance.

5. A Loop should be removed fromautomatic control warning appears.Remove the OPM 2001 from any con-trol loops and press OK to continue.Then, an About to begin check opticsstatus message briefly displays.

6. In the next screen, the system promptsyou to select the LCW state. Scroll toVSTACK and press Enter. The presentVSTACK value will display. Proceed tothe stack. A steady beam of lightshould be leaving the transceiver.

b. Remove the end cap from the retroreflectorbody.

c. Install the alignment sight in the retrore-flector body (Figure 4-1).

d. Refer to Figure 5-2:

1. Remove electronics housing (14).

2. Remove thumbscrew (2) and opticalenclosure cover plate (1).


July 2001


Model OPM 2001

e. Refer to Figure 4-3. Loosen the set screwssecuring the objective lens.

f. Slide the objective lens toward the apertureor away from the aperture.

g. During the adjustment, look through thealignment sight at the aperture crosshairs.Stop the adjustment when the crosshairsare in sharp focus and tighten the setscrews.

h. Remove the alignment sight from the retro-reflector body (Figure 4-1).

i. Reinstall the end cap assembly to the retro-reflector.

j. Reinstall optical enclosure cover plate (1,Figure 5-2) and secure with screw (2).

k. Use the HART Communicator to check theVSTACK and VLAMP voltages, make ad-

justments as necessary, and exit the checkoptics mode as follows:

1. When prompted for the next step, se-lect the REFRESH option. Note thecurrent VSTACK value.

2. When prompted again for the nextstep, select VLAMP to display the currentVLAMP value.

3. If VSTACK is not 2.0 ±0.1 V, adjust thegain per paragraph 7-3d.

4. If VLAMP is not 4.0 ±0.1 V, adjust the irisby moving the slider bar on LCW2mounting block per paragraph 7-3d.

5. Once the two voltages are properly set,select the EXIT option.

6. At the Return control loop to automaticcontrol message, return the OPM2001 to the automatic control loopspreviously removed and press Enter.

APERTURE

LCW 2

SETSCREWS

OBJECTIVELENS 35560011

Figure 4-3. Objective Lens Adjustment



Model OPM 2001

SECTION 5

13

15

14

16

18

19

20

21

22

23

24

25

27

26

3130

29

28

7

35

32

33

34

3637

38

39

40 41 4243

53

49

4847

46

45

50

4

444

52

51

54

55

56

55

57

60

61

62

59

63

64 6566

58

1

NOTE: NOT ALL PARTS SHOWNARE AVAILABLE FORPURCHASE SEPARATELY.FOR A LIST OF AVAILABLEPARTS, SEE SECTION 10.

3

2

35560020

5

6

8

8

9

17

11

12

10

Figure 5-1. Transceiver Module - Exploded View


July 2001


Model OPM 2001

SECTION 5TRANSCEIVER AND RETROREFLECTOR MODULES

5-1 TRANSCEIVER MODULE

The main components of the transceiver module(Figure 5-1) are optical assembly (1, Figure 5-1and Figure 5-2), air lens (58, Figure 5-1), andblower motor (5). The three components aremounted to mounting plate (34) and enclosed inweather housing (9). The optical assemblycontains all transceiver optical and electroniccomponents. Lifting and handling instructionsfor the transceiver and the retroreflector can befound in paragraph 2-5.

a. Optical System

The light source for the optical system is aspecial, long-life incandescent lamp. The

lamp contains a built-in lens that directslight forward through a 1/8 in. (3 mm) di-ameter crosshaired aperture.

Two Liquid Crystal Windows (LCWs) func-tion as shutters that either block or transmitlight. The LCWs are made of a normallytranslucent film that scatters the light strik-ing it. However, when an electric current isapplied to the film, the LCW becomestransparent and allows light to pass. Thesequence in which the LCWs turn on or offand the duration of each are software-controlled.

LEGEND FOR FIGURE 5-1 1. Optical Assembly 2. Power Cable 3. Communications Cable 4. Hose Clamp 5. Blower Motor 6. Hex Nut, 1/4-20 7. Lockwasher, 1/4 in. 8. Washer, 1/4 in. 9. Weather Housing 10. Mounting Plate 11. Washer, 1/4 in. 12. Pan Head Screw, 1/4-20 x 7/8 in. 13. Mounting Block 14. Toggle Clamp 15. Pan Head Screw, #8-32 x 3/4 in. 16. Pan Head Screw, #8-32 x 3/8 in. 17. Pan Head Screw, #8-32 x 7/8 in. 18. Filter Retainer 19. Wing Nut, 1/4-20 20. Filter (Coarse) 21. Filter (Fine) 22. Nut, 1/4-20 23. Filter Retainer

24. Pan Head Screw, #8-32 x 3/8 in. 25. Top Cover Plate 26. Cable Grip 27. Seal 28. Bolt, 1/4-20 x 1-1/4 in. 29. Rivet 30. Latch 31. Conduit Lock Nut, 1/2 in. 32. Gasket 33. Flange 34. Mounting Plate 35. Bolt, 1/4-20 x 5/8 in. 36. Bottom Cover Plate 37. Standoff, #6-32 x 1/2 in. 38. External Star Washer, #6 39. Screw, #6-32 x 1/4 in. 40. Ground Cable 41. Termination Board 42. External Star Washer, #6 43. Screw, #6-32 x 1/4 in. 44. Adapter 45. Filter Base 46. Filter Element Assembly

47. Filter Cover 48. Flat Washer, 3/8 in. 49. Wing Nut, 3/8-16 50. Hose 51. Screw, #10-32 x 3/8 in. 52. External Star Washer, #10 53. Purge Air Failure

Flow Switch Cable 54. Purge Air Failure Flow Switch 55. Straight Connector 56. Air Tubing 57. Stud 58. Air Lens Assembly (Includes

items 59 through 62) 59. Ball Seat 60. Seal Plate 61. Check Valve 62. Adapter 63. Spherical Washer, 3/8 in. 64. Spherical Hex Nut, 3/8-16 65. Hex Nut, 5/16-18 66. Lockwasher, 5/16



Model OPM 2001

NOTE: NOT ALL PARTS SHOWN ARE AVAILABLEFOR PURCHASE SEPARATELY. FOR A LISTOF AVAILABLE PARTS, SEE SECTION 10.

2

1

68

67

6665

61

64

63

62

61

60

17

16

15

18

13

3

4

5

6

7

712

8

9

10

11

19

20

21

22

23

48

4647

44

45

50

49

52

51 5354

5556

57

5859

69

57

58

5943

42

41

4039

38

37

36

35

34

33 32

31

28

28

30

29

27

26

25 24

14

35560017

Figure 5-2. Transceiver Optical Assembly - Exploded View


July 2001


Model OPM 2001

LEGEND FOR FIGURE 5-2 1. Cover Plate 2. Thumbscrew, #6-32 x 3/8 in. 3. Splitter Base 4. Socket Head Screw,

#6-32 x 1 in. 5. Beam Splitter 6. Socket Head Screw,

#4-40 x 1/2 in. 7. O-Ring 8. Aperture 9. LCW 1 10. Aperture 11. Mounting Block 12. Retainer 13. Socket Head Screw,

#6-32 x 3/8 in. 14. Electronics Housing 15. Lamp Mounting Adapter 16. Lamp 17. Lamp Holder 18. Socket Head Screw,

#6-32 x 1/2 in. 19. Socket Head Screw,

#6-32 x 1/2 in. 20. Set Screw, 1/4-20 x 1/4 in. 21. Heater

22. Optical Mounting Channel 23. CAL/CHECK Pushbutton 24. Pan Head Screw, #8-32 x 1/4 in. 25. Latch Clip 26. Conduit Lock Nut, 1/2 in. 27. Mounting Plate 28. Cable Grip 29. Communication Cable 30. Power Cable 31. Flat Washer, 1/4 in. 32. Lockwasher, 1/4 in. 33. Hex Head Bolt, 1/4-20 x 1 in. 34. Window Flange 35. Gasket 36. Threaded Retaining Ring 37. Front Window 38. O-Ring 39. Socket Head Screw,

#6-32 x 5/8 in. 40. Gasket 41. Access Plate 42. Latch Clip 43. Rivet 44. Latch 45. Pan Head Screw, #8-32 x 1/4 in. 46. Pan Head Screw, #6-32 x 3/8 in.

47. External Star Washer, #6 48. Standoff, #6-32 x 1/2 in. 49. Ground Cable 50. Stack LON Board 51. Socket Head Screw,

#6-32 x 3/8 in. 52. Internal Star Washer, #6 53. Detector Mount 54. Green Filter 55. Detector 56. Detector/Amplifier Board 57. Internal Star Washer, #6 58. Socket Head Screw,

#6-32 x 3/8 in. 59. Standoff, #6-32 x 1/2 in. 60. Socket Head Screw,

#4-40 x 1/2 in. 61. O-Ring 62. Reflector 63. LCW 2 64. Aperture 65. Mounting Block 66. Iris 67. Objective Lens 68. Lens Retainer 69. Lamp Power Supply

Each measurement cycle consists offour different light path modes; eachmode produces a different voltage.The four measurement modes arestack, ambient, dark, and lamp andare explained as follows:

1. Stack Mode. Refer to Figure 5-3. Dur-ing the stack mode, the light beampasses through the aperture (with

crosshairs), LCW 1, and beam splitter.Then, the beam travels through theobjective lens, LCW 2 (center seg-ment), and an air window; across thestack; and into a retroreflector. The ret-roreflector, by means of a corner cube,reflects the light back through thestack, air window, LCW 2, iris, and ob-jective lens. The beam strikes thebeam splitter and is reflected into the

APERTURE(WITH CROSSHAIRS)

BEAMSPLITTER IRIS

OBJECTIVELENS

COMBINATIONLCW 2DETECTOR

LCW 1

LAMP

35560018

Figure 5-3. Stack Light Path



Model OPM 2001

LCW 1 COMBINATIONLCW 2

LAMP

DETECTOR35560004

OBJECTIVELENS

Figure 5-4. Ambient Light Path

detector. The detector (a photodiode)converts the light to a voltage that canbe processed. The desired spectral re-sponse is achieved by a narrow greenband filter on the detector.

2. Ambient Mode. Refer to Figure 5-4. Inthe ambient mode, LCW 1 blocks thelamps light, preventing it from everreaching the detector. While the lamplight is blocked, LCW 2 allows ambientlight to reach the objective lens, beamsplitter, and detector.

3. Dark Mode. Refer to Figure 5-5. In thedark mode, both LCWs are off. Thevoltage measured during the darkmode is used to compensate for any

internal light leakage within thetransceiver.

4. Lamp Mode. Refer to Figure 5-6. Thelamp mode allows the OPM 2001 tocompensate for the effects of an agingbulb. In this mode, the inner segmentof LCW 2 is off, stopping the beamfrom reaching the air window and pre-venting the entrance of ambient light.The lamp beam is directed through theobjective lens and the outer ring seg-ments of LCW 2 to an internal retrore-flector located behind the outer ringsegments. The beam is then directedback through the objective lens to thebeam splitter and into the detector. Theiris installed over the objective lens canbe adjusted to keep the lamp voltage atapproximately 4.0 V.

LCW 1

LAMP

DETECTOR35560005

COMBINATIONLCW 2

OBJECTIVELENS

Figure 5-5. Dark Mode


July 2001


Model OPM 2001

35560006

LCW 1

DETECTOR

LAMP

INTERNALRETROREFLECTOR

COMBINATIONLCW 2

IRIS

Figure 5-6. Lamp Light Path

b. Filters and Zero Jig

An external neutral density filter check isused to meet EPA requirements concerningmonitor accuracy and calibration. To checkthe monitor, remove the window accessplate (Figure 5-7) and position the zero jigonto the window flange. Then, insert EPA-certified neutral density filters in the zero jig,one at a time, and compare the filter valueswith the actual monitor readings. This com-parison shows the monitors accuracy. Re-fer to paragraph 3-7g for completeinstructions.

c. Detector/Amplifier PC BoardThe detector is a photodiode that convertslight energy to a voltage. A green filter infront of the detector is used to achieve thedesired spectral response. The filtersmaximum response is at 550 nm (Figure5-8). At below 400 nm and above 700 nm,the filter transmits less than 2% of the light.

Detector CR1 (Figure 5-9) is mounted to thedetector/amplifier PC board, which amplifiesthe signal. The board contains a 2-positionjumper to adjust the range of gain. If thejumper is in the low position (JM1), the gain

LATCHWINDOWACCESSPLATE

WINDOWFLANGE

ISOLATIONWINDOW

ZERO JIGLOCATING PIN

WINDOWCLEANING

AREAZERO JIG

35560007

Figure 5-7. Zero Jig Mounting Location



Model OPM 2001

Figure 5-8. Effective Spectral Response Curve

adjustment is from 1 to 10. In the high posi-tion (JM2), the gain is from 10 to 100. Po-tentiometer R1 allows adjustment within therange determined by the jumpers (Figure5-10).

d. Stack LON Board

Refer to Figures 5-9 and 5-11. The stackLON board is mounted to the opticalmounting channel. The electronics on thestack LON board include the communica-tions electronics, temperature sensor,heater controller, purge air failure flowswitch input modules, and DC power sup-plies. Power supply 1 (PS1) supplies power

to the lamp power supply board and elec-tronics. Power supply 2 (PS2) suppliespower to LCW 1, LCW 2, and a status LED.

e. Termination Board

Termination board (41, Figure 5-1) is in-stalled on mounting plate (34) and providesa connection point for cables to and fromthe transceiver. The board provides con-nections for the transceiver and retroreflec-tor purge air failure flow switches, stackLON board power supplies, and AC powerinput. Refer to Figure 2-9 or 2-10 for an il-lustration and wiring schematic of the termi-nation board.

JM1 LOW GAIN

JM2 HIGH GAIN

STACK LONBOARD

DETECTOR (CR1)(MOUNTED ON

REVERSE SIDE)

R1DETECTOR/AMPLIFIER

BOARD

LAMPPOWER SUPPLY

BOARD

35560008

Figure 5-9. Optical Mounting Channel(with Boards)


July 2001


Model OPM 2001

AMPLIFIERCIRCUIT

AMPLIFIERCIRCUIT

+15 VDC -15 VDC+15 VDC -15 VDC

DETECTOR(CR1)

POTENTIOMETER(R1)

NOTE: -0.5 VDC AND +4.75 VDC ARE DETECTOR AMPLIFIER SATURATION VALUES. TYPICALLY, LAMPMODE VOLTAGE READINGS ARE +3.0 VDC TO +4.0 VDC AND STACK MODE VOLTAGE READINGSARE +1.5 VDC TO +2.0 VDC. POTENTIOMETER R1 CAN BE ADJUSTED TO PREVENT AMPLIFIERSATURATION. POTENTIOMETER R1 DOES NOT AFFECT CALIBRATION.

JM1(LOW)(X10)

JM2(HIGH)(X100)

-0.5 TO +4.75 VDC(SEE NOTE)

35560009

Figure 5-10. Detector Circuit

Figure 5-11. Stack LON Board



Model OPM 2001

f. Heater

Allowing the temperature in the optical unitto reach or fall below freezing could result inimproper OPM 2001 operation. For this rea-son, a heater is installed on the opticalmounting channel. The temperature circuitryon the stack LON board turns the heater onwhen the temperature in the transceiver as-sembly is below 85.1°F (29.5°C) and offwhen the temperature in the transceiver as-sembly is above 86°F (30°C).

g. Lamp Power Supply

Refer to Figure 5-9. The lamp power supplyis mounted to the optical mounting channel.It is a 12 V, 40 W power supply used to il-luminate the lamp.

5-2 RETROREFLECTOR MODULE

The retro-reflector module is similar to thetransceiver module. However, instead of an op-tical assembly (1, Figure 5-1), the retroreflectormodule has a corner cube reflector mounted tothe air lens assembly (Figure 5-12).

The retroreflector consists of retroreflector body(2, Figure 5-12) and end cap and corner cubeassembly (3). The latter consists of corner cubeholder (4), corner cube (5), gasket (6), and endcap (zero reflector) (7). Light from the trans-ceiver passes through the stack and into the ret-roreflector. The corner cube reflects the beamback along the same path. Refer to Section 4for more information on checking and aligningthe transceiver and retroreflector modules.

1

24

5

67

3

8

9

NOTE 1

35560023

1.

2.

3.

NOTES:

NOTE 2

NOT ALL PARTS SHOWN ARE AVAILABLE FORPURCHASE SEPARATELY. FOR A LIST OFAVAILABLE PARTS, SEE SECTION 10.

DIFFERENT CORNER CUBES AND HOLDERSARE USED AS FOLLOWS:

THE FLAT SURFACE SIDE OF THE END CAP IS A“ZERO-REFLECTOR” AND CAN BE USED TO SIMULATE100% OPACITY.

PATHLENGTH3 to 10 ft (0.915 to 3.05 m)

10 to 20 ft (3.05 to 6.1 m)

20 to 26 ft (6.1 to 7.9 m)

CORNER CUBE0.5 in. (12.7 mm) Diameter

Corner Cube1 in. (25.4 mm) Diameter

Corner Cube1.5 in. (38.1 mm) Diameter

Corner Cube

1. Air Window2. Retroreflector Body3. End Cap and Corner Cube

Assembly4. Corner Cube Holder5. Corner Cube (Retroreflector)6. Gasket7. End Cap (Zero Reflector)8. Retaining Strap9. Screws (3)

Figure 5-12. Retroreflector and Air Lens Assembly


July 2001


Model OPM 2001

During calibration, it is possible to simulate100% opacity by removing the end cap and cor-ner cube assembly. Upon removal, reverse theend cap and reinstall with the flat (zero reflector)side facing the retroreflector body.

5-3 PURGE AIR FAILURE FLOW SWITCH

The OPM 2001 contains two purge air failureflow switches (Figure 5-13). One switch ismounted on the transceiver module mountingplate; the other is mounted on the retroreflectormodule mounting plate. Each switch continu-ously monitors the differential pressure acrossits respective air lens assembly. If the differen-tial pressure falls below a preset value, the af-fected switch opens. The purge air failure flowswitch interface module sends an alarm signalthrough the stack LON board to the intelligentelectronics. The intelligent electronics distin-guishes which unit has failed (transceiver or ret-roreflector) and displays the flow switch statususing a HART Communicator.

Figure 5-13. Air Lens Assembly and Purge AirFailure Flow Switch



Model OPM 2001

5-4 AIR LENS ASSEMBLY

An air lens assembly (Figure 5-14) is mountedto the mounting plate inside the weather hous-ing of both the transceiver and retroreflectormodules. Each air lens, by receiving purge airfrom its own blower, is capable of maintaining aclean space of air between the modulesopticsand the stack gases and particulates. A manu-ally positioned sliding seal plate is used to pro-tect the instrument from flue gases andparticulates when the blower is off. Ball-jointconstruction of the assembly provides for hori-zontal and vertical alignment adjustments. Referto paragraph 5-1.

Coarse and fine filters (20 and 21, Figure 5-1)are located at the bottom of the weather hous-ings. The filters remove airborne particulates asair is drawn through the filters by the suction ofthe blower. Secondary filter element (46)mounts directly to the blower intake. The filterscan be easily removed for cleaning and reuse.Refer to paragraph 7-2d.

8

12

3

4

5

6

7

13

1211

10

9

NOTE: NOT ALL PARTS SHOWN AREAVAILABLE FOR PURCHASESEPARATELY. FOR A LIST OFAVAILABLE PARTS, SEE SECTION 10.

35560033

1. Convex Washers (4) 2. Concave Washers (4) 3. Adjusting Nuts (4) 4. Housing 5. Upper Adapter 6. Check Valve 7. Lower Adapter

8. Seal Plate 9. Seal Springs 10. Ball Plate Screws (2) 11. Ball Plate 12. Screw 13. Stud (4)

Figure 5-14. Air Lens Assembly - Exploded View


July 2001


Model OPM 2001

1

2

3

4

5

6

8

7

3

9

10

11

12

13

14 15

29170015

SECTION 6INTELLIGENT ELECTRONICS

6-1 GENERALThe intelligent electronics is the control unit ofthe OPM 2001. It continuously receives digitalsignals from the transceiver via the communica-tions link and converts them into readings ofopacity, transmittance, optical density, extinc-tion, and dust density. In addition, the intelligentelectronics sends commands to the transceiverto initiate diagnostic tests and provides an op-erator interface via HART communications.

Two types of intelligent electronics are avail-able: the standard general purpose version forindoor use and the optional Type 4X weather-proof version for outdoor use.

6-2 INTELLIGENT ELECTRONICS (GENERALPURPOSE)The general purpose intelligent electronics unit(Figure 6-1) consists of two boards: the IG-1software board (6) and the HART daughterboard (15).

a. IG-1 Software BoardThe IG-1 software board (6, Figure 6-1 andFigure 6-2) contains the software program,three LED indicators, and connections tothe transceiver, power source, and HARTdaughter board (15, Figure 6-1).

1. 4-Pin Plug 2. 3-Pin Plug 3. Screw, M3 x 6 4. Endplate 5. Enclosure 6. IG-1 Software

Board 7. Lock Nut, #4-40 8. Endplate

9. 6-Pin Plug 10. 9-Pin Plug 11. Grommet 12. Standoff, #4-40 x 15/16 in. 13. External Star Lockwasher,

#4-40 14. Screw, #4-40 x 1/4 in. 15. HART Daughter Board

Figure 6-1. General Purpose Intelligent Electronics - Exploded View



Model OPM 2001

1

1 (+)

2LON

U4

24 VDC

F11/2ASLO BLO

3 (EARTH GND)2 (- )

TO LON

FAULT LED

COMM LED

TO RS-232ON HARTDAUGHTERBOARDTO 24 VDC

POWERSOURCE

NOT USED

SOFTWAREPROGRAM

POWER LED

IN A NEMA 4X INTELLIGENT ELECTRONICS, THE 24 VDCCONNECTOR CONNECTS TO A UNIVERSAL POWER SUPPLYTHAT CONVERTS THE INCOMING LINE VOLTAGE TO 24 VDC.

NOTE:

29170007

Figure 6-2. IG-1 Software Board

1. IG-1 Software. The software programthat controls the intelligent electronicsresides in PROM U4 (Figure 6-2). Tocheck the version level of your soft-ware, access the REVIEW menu usingthe HART Communicator. Refer toSection 3 for more information. It isonly necessary to replace the PROMfor a software upgrade. The factory willdetermine if the software change ismandatory for units already shipped. Ifyou require a replacement board, thenew board will contain the latest soft-ware revision.

2. LEDs. Three LEDs are mounted to theside of the software board: FAULT,COMM, and POWER.

(a) The yellow FAULT LED turns onwhen a fault occurs on the IG-1software board.

(b) The COMM LED indicates whendata is transferring between thetransceiver and the intelligentelectronics. A green light indicates

the intelligent electronics is re-ceiving information. A red light in-dicates the intelligent electronics issending information.

(c) The green POWER LED lightswhen the power source to the in-telligent electronics is turned on.

3. LON Connection. The wiring that at-taches to the LON connector providesthe communication link between theintelligent electronics and thetransceiver.

4. +24 V Connection. The +24 V con-nector is wired directly to the HARTdaughter board.

5. RS-232 Connector. The 9-pin con-nector establishes a communicationlink between the HART daughter boardand the software board.

6. F1 Fuse. This Pico II, 1/2 amp, Slo Blofuse provides board circuit protectionfrom the incoming power source.


July 2001


Model OPM 2001

4-20mALOOPTO STACK

RELAYCONTACTS

RELAY 6

RELAY 5

RELAY 2

RELAY 1

RELAY 3

RELAY 4

ANALOGOUTPUTS

DIGITALINPUT

J5

J2

J1

J11

P1P1

J9

J6

J3

U7

3D39650G REV

24VDC

+

+

+

+

+

HART

J7

1

2

3

+

+

+

+

-

-

-

-

-

-

-

-

-

J4

RS-232

J8

+

+

+

+

+

+

+

+

+

+

+

+

+

4-20 mALOOP TOSTACK

TO DIGITALINPUT

REAL-TIMECLOCK AND BATTERY

TO 24 VDCPOWERSOURCE

TO RS-232ON IG-1SOFTWAREBOARD

TO RELAYCONTACTS

RELAY JUMPER BLOCKS

TO ANALOGOUTPUTDEVICES

TO HARTCOMMUNICATOR

SWITCHES(MUST BE IN UPPOSITION FORINTERNALLY POWEREDSIGNAL LOOPS)

NOTE: IN A NEMA 4X INTELLIGENT ELECTRONICS UNIT, THE 24 VDCCONNECTOR CONNECTS TO A UNIVERSAL POWER SUPPLY THATCONVERTS THE INCOMING LINE VOLTAGE TO 24 VDC. 29170002

Figure 6-3. HART Daughter Board

b. HART Daughter Board

The HART daughter board (15, Figure 6-1and Figure 6-3) contains the real-time clock,relay jumper blocks, and connections to thetransceiver, power source, HART Commu-nicator, analog outputs, relay contacts, anddigital input.

1. Clock. The HART daughter boardcontains a real-time clock that receivespower from an on-board rechargeablelithium battery during power outagesand when the board is removed fromthe intelligent electronics.

2. 4-20 mA LOOP TO STACK Connection(J2). The wiring that attaches to the4-20 mA LOOP TO STACK connectorestablishes a 4-20 mA signal loop be-tween the intelligent electronics andthe transceiver. The HART Communi-cator only operates on the 4-20 mAsignal loop. By running the signal loopbetween the intelligent electronics andthe transceiver, you can use the HARTCommunicator to interface with theOPM 2001 at either the intelligent

electronics or transceiver installationsite.

3. 24 VDC Connection (J3). The 24 VDCconnector is wired directly to the 24VDC power source. Rosemount offersan optional 115 VAC or 220 VAC/24VDC power supply that will transformthe voltage to the 24 VDC needed.

4. Digital Input (J5). The digital inputconnector gives you the opportunity toinitiate a zero/span check via a remoteinput such as a computer control sys-tem. This is in addition to the sched-uled zero/span check configured withthe HART Communicator. The contactinput is interrogated by the intelligentelectronics with 5 VDC.

5. Relay Contact Connection (J1). Therelay contact connector can be wired toexternal devices that utilize OPM 2001status indications. The six relays areconfigured using the HART Communi-cator. Refer to paragraph 3-9a for moreinformation.



Model OPM 2001

6. Analog Output Connection (J6). Theanalog output connector can be wired toa recorder, controller, or computer thatutilizes isolated analog readings from theOPM 2001. The three analog outputs aredetermined by the PV, SV, and TV val-ues configured using the HART Com-municator. Analog output 1 (AO1), whichalways has the PV value, also carries thedigital HART communications signal.Refer to paragraph 3-6d for moreinformation.

7. HART Connection (J7). The intelligentelectronics provides two banana jackreceptacle cable assemblies to plugthe HART Communicator into the 4-20mA signal loop. The cable assembliesare located on the endplate of the intel-ligent electronics, and their terminalsplug into HART connector J7 on theHART daughter board. Refer to para-graph 3-2 for more information on at-taching the HART Communicator to thesignal loop.

8. Switches 1, 2, and 3. These switchescan be configured in the up position topower the analog output circuit by theOPM 2001 or in the down position topower the analog output circuit by thefield device receiving the analog outputsignal from the OPM 2001.

9. Relay Jumper Blocks (J9 and J11).The relays on the HART daughterboard are now configurable via twojumper blocks: J9 and J11 (Figure 6-4).This new feature was added to provideadditional flexibility when configuringthe instruments alarm outputs. J9 canbe configured so the instruments relaycontacts are either normally energizedor normally de-energized during normaloperating conditions. J11 can be con-figured so the contacts are either nor-mally open or closed during normaloperating conditions. These terms areexplained below:Normally Open Relay A relay withopen contacts when it is in an unpow-ered state.Normally Closed Relay A relaywith closed contacts when it is in anunpowered state.

Normally Energized Relay A relaywith its coil energized during normaloperating conditions.Normally De-Energized Relay Arelay with its coil de-energized duringnormal operating conditions.Normal Operating Conditions Theoperating condition when no alarms orspecial states are active.The normally energized/normally de-energized states of relay 6 are re-versed in the on-board logic. Conse-quently, the jumper position for relay 6is the opposite of the jumper positionsfor relays 1 through 5.Two example relay configurations aredefault and failsafe.(a) Default Configuration. The default

configuration of the relays mini-mizes the amount of nuisancealarms during power interruptionsto the instruments electronics.This configuration also minimizespower usage and maximizes relaylife during normal operations.In the default configuration, relays1 through 5 are normally de-energized and normally open andrelay 6 is normally energized andnormally closed. Therefore, all sixcontacts are open during normaloperating conditions and closewhen an alarm condition occurs. Ifa power failure occurs, relays 1through 5 open and relay 6 closes.

(b) Failsafe Configuration. The failsafeconfiguration of the relays placesnormally open relay contacts in aclosed state during normal operat-ing conditions and in an open stateduring an alarm or no powercondition.In the failsafe configuration, all ofthe relays are normally energizedand normally open. Therefore, allof the relay contacts are closedduring normal operating conditionsand open when an alarm or nopower condition occurs.


July 2001


Model OPM 2001

4-20mALOOPTO STACK

RELAYCONTACTS

RELAY 6

RELAY 5

RELAY 2

RELAY 1

RELAY 3

RELAY 4

ANALOGOUTPUTS

DIGITALINPUT

J5

J2

J1

J11

P1P1

J9

J6

1

2

3J3

U7

3D39650G REV

24VDC

+

+

+

+

+

HART

J7

+

+

+

+

-

-

-

-

-

-

-

-

-

J4

RS-232

J8

+

+

+

+

+

+

+

+

+

+

+

+

+

DEFAULT CONFIGURATION

FAILSAFE CONFIGURATION

HART DAUGHTER BOARD

1717

17

1212

12

1818

18

66

6

1111

11

55

5

1616

16

1010

10

44

4

1515

15

99

9

33

3

1414

14

88

8

22

2

1313

13

77

7

11

1

RELAY 1

RELAY 1

RELAY 2

RELAY 2

RELAY 3

RELAY 3

RELAY 4

RELAY 4

RELAY 5

RELAY 5

RELAY 6

RELAY 6

J9

J9

J11

NORMALLYDE-ENERGIZED

NORMALLYENERGIZED

NORMALLYENERGIZED

NC

NO

29170001

17

12 186

115

16104

1593

1482

1371

J11

NO

Figure 6-4. HART Daughter Board Relay Contact Configurations

6-3 TYPE 4X INTELLIGENTELECTRONICS (OPTION)

In addition to the IG-1 software board and theHART daughter board of the intelligent elec-tronics unit, the Type 4X version (Figure6-5) also includes a weatherproof enclosure,power supply, optional heater, and terminationboard.

a. IG-1 Software Board

The IG-1 software board (Figure 6-2 and19, Figure 6-5) contains the software pro-gram, three LED indicators, and connec-tions to the transceiver, power source, andHART daughter board (9).

The Type 4X and the general purpose intel-ligent electronics units use the same soft-ware board. The only difference that existsis in the 24 VDC connection. The softwareboard in the general purpose unit is wireddirectly to a 24 VDC power source; thesoftware board in the Type 4X unit is wiredto a universal power supply that transformsthe incoming line voltage into the required24 VDC.

b. HART Daughter Board

The HART daughter board (Figure 6-3 and9, Figure 6-5) contains the real-time clock,relay jumper blocks, and connections to thetransceiver, power source, HART Commu-nicator, analog outputs, relay contacts, anddigital input.

The general purpose and Type 4X units usethe same HART daughter board, but twodifferences exist. The HART daughter boardin the general purpose unit is wired directlyto a 24 VDC power source; the HARTdaughter board in the Type 4X unit is wiredto a universal power supply that transformsthe incoming line voltage into the required24 VDC.

The other difference is the HART Communi-cator connection location. On top cover plate(15) of the Type 4X unit are two bananajacks, J2 and J3, used to attach the HARTCommunicator to the 4-20 mA signal loop.These banana jacks connect to HART con-nector J7 on the HART daughter board viaconnector J1 on the top cover plate.



Model OPM 2001

1

2

3

4

56

1011

7

8

9J712

J3

J2

J1

13

17

18

19

14

15

16

20

2122

23

24

29170016

1. Enclosure 2. Cable Grip 3. Conduit Lock Nut, 1/2 in. 4. Standoff, #6-32 x 1 in. 5. Termination Board 6. Screw, #6-32 x 1/4 in. 7. 6-Pin Plug 8. 9-Pin Plug 9. HART Daughter Board 10. Standoff, #4-40 x 1 in. 11. Standoff, #4-40 x 15/16 in. 12. Screw, #4-40 x 1/4 in.

13. Cable 14. Screw, #10-32 x 3/8 in. 15. Top Cover Plate 16. Standoff, #10-32 x 4 in. 17. 4-Pin Plug 18. 3-Pin Plug 19. IG-1 Software Board 20. Screw, #6-32 x 1/4 in. 21. Power Supply 22. Standoff, #6-32 x 1/2 in. 23. Heater (Optional) 24. Mounting Plate

Figure 6-5. Type 4X Intelligent Electronics - Exploded View


July 2001


Model OPM 2001

c. Type 4X Enclosure

Enclosure (1, Figure 6-5) is weatherproof sothe intelligent electronics can be installedoutdoors. Top cover plate (15) providesconvenient access to the 4-20 mA signalloop needed to attach the HART Communi-cator operator interface.

d. Termination Board

Termination board (5, Figure 6-5 and Figure6-6) connects to the incoming line voltageand supplies the operating voltage to thepower supply and heater. The 5 A, 250 VSlo Blo fuse on the termination board pro-tects the system components from the in-coming voltage.

!

L N

LN LN

48

50

B3

4G

RE

V

TO POWERSUPPLY

TO INCOMINGLINE VOLTAGE

FUSE

TO HEATER

29170017

J2 J3

J1

F15A,250VACSLO BLO

Figure 6-6. Termination Board

e. Power SupplyUniversal power supply (21, Figure 6-5 andFigure 6-7) transforms the incoming linevoltage into the 24 VDC used by the IG-1software board and the HART daughterboard. The power supply receives powerthrough its connection to the terminationboard (Figure 6-6).

f. Heater (Optional)Optional 300 watt heater (23, Figure 6-5),available in 115 VAC or 220 VAC depend-ing on the customer requirement, keeps theType 4X unit components at an ambientoperating temperature. If the ambient tem-perature falls below 60°F (16°C), the heaterturns on. If the temperature rises above75°F (24°C), the heater turns off. Theheater receives power through its connec-tion to the termination board (Figure 6-6).

Figure 6-7. Power Supply



Model OPM 2001


July 2001


Model OPM 2001

SECTION 7MAINTENANCE AND SERVICE

Install all protective equipment coversand safety ground leads after equip-ment repair or service. Failure to in-stall covers and ground leads couldresult in serious injury or death.

7-1 GENERALThis section describes the routine maintenanceof the Rosemount OPM 2001 Opacity/DustDensity Transmitter. The amount of mainte-nance required depends on the environment towhich the instrument is subjected. A transmitterthat is subjected to extremely dusty conditions,vibration, and movement will require considera-bly more maintenance than a unit that is rigidlymounted in a clean, dust-free atmosphere.

A preventive maintenance schedule is includedin Appendix B. Ensure all routine maintenanceprocedures are performed at the specifiedintervals.

7-2 PREVENTATIVE MAINTENANCEa. If the opacity/dust density transmitter read-

ing is too high, check the alignment of theoptics. If the unit is properly aligned, thenclean the transceiver window and the retro-reflector corner cube. If the reading is stilltoo high, recalibrate the unit.

b. Inspect and clean the transceiver windowand the retroreflector corner cube asfollows:

1. Remove weather housings (9, Figure5-1) on the transceiver and retrore-flector modules.

2. Remove electronics housing (14, Fig-ure 5-2) from the optical bench assem-bly by releasing the four toggle clampsthat hold the housing to mounting plate(27).

3. Release the toggle latches on the frontleft side of the transceiver and removewindow access plate (41) and gasket(40).

4. Clean window (37) with a good lenscleaning solution and a lens wipe. DONOT use a towel or rag that mayscratch the window or leave lint behind.

5. Install window access plate (41) andgasket (40).

6. Install electronics housing (14).

7. Unscrew endcap on the retroreflectormodule (Figure 4-1). The corner cubeis mounted inside the endcap.

8. Clean the corner cube with a good lenscleaning solution and a lens wipe. DONOT use a towel or rag that mayscratch cube or leave lint behind.

9. Install the endcap on the retroreflector.

10. Install weather housings (9, Figure 5-1)on the transceiver and retroreflectormodules.

c. Check the alignment of the modules usingthe optical alignment sight. If necessary,realign modules as described in Section 4.



Model OPM 2001

d. If the unit is installed in a dirty environment,clean the external filters that are located onthe weather housings every two months(every three months if in a clean environ-ment) as follows:

1. Remove the filter retainer by unscrew-ing the wing nuts (Figure 7-1).

2. Remove the coarse and fine filters fromthe bottom of the weather housing.

35560034

WINGNUT

FILTERRETAINER

WEATHERHOUSING

FINEFILTER

COARSEFILTER

Figure 7-1. External Filters - Exploded View

3. Immerse the filters in a mild detergentsolution such as common dishwashingdetergent. Gently wring out each filter.

4. Install the filters. Make sure the finefilter is installed before the coarse filter.

5. Install the filter retainer and secure withthe wing nuts.

e. Check the internal filters on the transceiverand retroreflector modules after every otherexternal filter cleaning. If a filter is visiblydirty, clean as follows:

1. Remove the entire filter assembly byunscrewing the filter base (Figure 7-2)from the blower motor.

2. Unscrew the wing nut from the filterbase and remove the washer.

3. Remove cover and filter retainer andslide the filter element from the filtercore.

4. Immerse the filter in a mild detergentsolution such as common dishwashingdetergent. Gently wring out the filter.

5. Slide the filter element onto the filtercore.

6. Install the retainer, cover, and washerand secure the filter assembly with thewing nut.

7. Install the filter assembly onto theblower motor.


July 2001


Model OPM 2001

WINGNUT

WASHER

COVER

FILTERRETAINER

FILTER

FILTERCORE

FILTERBASE

24670050

Figure 7-2. Internal Filter - Exploded View

7-3 REPAIR

a. Optical Assembly (1, Figure 5-1).

1. Removal.

The optical enclosure cover shouldonly be removed in a clean, dust-freeenvironment. Unless the transceiver ismounted in a clean area, remove theoptical assembly from the stack andperform repairs in a suitable place.Use the following procedure to removethe optical assembly.

A sliding seal plate on the air lens as-sembly prevents exhaust gases frombacking up into the optical assembly.Be sure to close the seal plates when-ever the purge air supply is inter-rupted. Failure to close the plates canlead to equipment damage.

(a) Remove weather housing (9).

(b) Close air window seal plate (60).

(c) Turn off power to the transceiverand blower.

(d) Unplug power cable (2) and com-munications cable (3) from opticalassembly (1).

(e) Remove four nuts (65) and lock-washers (66) that secure opticalassembly (1) to air lens assembly(58) and remove the opticalassembly.

(f) Replace weather housing (9) onthe transceiver.

(g) Set optical assembly (1) in a cleanarea.

2. Installation.

(a) Remove weather housing (9) fromthe transceiver.

(b) Secure optical assembly (1) to airlens assembly (58) with four lock-washers (66) and nuts (65).



Model OPM 2001

(c) Plug communications cable (3) andpower cable (2) into optical assem-bly (1).

(d) Turn on power to the transceiverand blower.

(e) Open air window seal plates (60).

(f) Install weather housing (9).

b. Lamp Replacement

1. Remove the optical assembly from thetransceiver module per paragraph7-3a1.


3. Remove thumbscrew (2) and coverplate (1).

4. Disconnect the lamp lead wire termi-nals from lamp power supply board(69).

5. Unscrew and remove lamp (1, Figure7-3) and mounting adapter (2) fromlamp holder (3).

6. Thread the new lamp (1) with newmounting adapter (2) into lamp holder(3) until tight.

7. Loosen the mounting adapter setscrew to adjust the lamp position. En-sure the bulb filament remains parallelto the bottom plate of the optic chan

nel. Position about 1/2 in. (12.7 mm) oflamp (1) out of lamp holder (3).

8. Connect the lamp lead wire terminalsto lamp power supply board (69, Figure5-2).

9. Reinstall cover plate (1) and securewith thumbscrew (2).

10. Recalibrate the opacity transmitter.Refer to the offline calibration proce-dure per paragraph 3-7b.

11. Recalibrate the zero jig per paragraph7-4a.


13. Install optical assembly (1, Figure 5-1)in the transceiver module per para-graph 7-3a2.

35560015

3

1

2

1. Lamp 2. Mounting Adapter 3. Lamp Holder

Figure 7-3. Lamp Replacement


July 2001


Model OPM 2001

c. Detector/Amplifier Board Replacement

1. Remove optical assembly (1, Figure5-1) from the transceiver module perparagraph 7-3a1.


Figure 7-4. Detector/Amplifier Board

3. Disconnect the plug-in connector at J1(Figure 7-4).

4. Remove screws (16, Figure 7-5) andstar washers (15) securing detec-tor/amplifier board (14) to the opticalmounting channel.

5. Remove the detector/amplifier board(14) from the optical mounting channel.

6. Check the jumper at JM1 or JM2 onthe old board (Figure 7-4). Ensure thereplacement boards jumper is at thesame position (JM1 or JM2).

7. Install the new board to the mountingchannel and secure with four screws(16, Figure 7-5) and star washers (15).

8. Reconnect the plug-on connector to J1(Figure 7-4).

9. Refer to paragraph 7-3d and check thegain of the new detector/amplifierboard.



Model OPM 2001

1. Cover Plate 2. Thumbscrew 3. O-Ring 4. Aperture 5. LCW 1 6. Aperture 7. Socket Head Screw 8. LCW 1 Plug-in Connector 9. Socket Head Screw 10. Beam Splitter 11. Detector Mount 12. Green Filter 13. Detector 14. Detector/Amplifier Board 15. Internal Star Washer 16. Socket Head Screw 17. Reflector 18. LCW 2 19. Aperture 20. LCW 2 Plug-in Connector 21. Objective Lens and Iris

Figure 7-5. Beam Splitter Adjustment and LCW Replacement

d. Gain Adjustment

1. Apply power and ensure the LONcommunications is connected to theoptical assembly.

(a) If the optical assembly has beenremoved from the transceivermodule, connect the power andLON test cables supplied with theOPM 2001 to power cable (30,Figure 5-2) and communicationscable (29). Connect the power testcable to the correct AC voltagesource, and connect the test LON

cable to the LON (ECHELON)connector on the intelligentelectronics.

(b) If the optical assembly is stillmounted to the transceiver mod-ule, remove weather housing (9,Figure 5-1) and electronics hous-ing (14, Figure 5-2).

2. Using the HART Communicator, viewthe VSTACK or VLAMP voltages from theFLD DEVICE VOLTS submenu of thePROCESS VARIABLES menu.


July 2001


Model OPM 2001

3. If VSTACK is between +1.5 and 2.0 Vdc,go to step 4. If not, adjust potentiome-ter R1 on the detector/amplifier board(Figure 7-4) until VSTACK is +2.0 ±0.1 V.

(a) If potentiometer R1 is turned all theway up and the voltage is still toolow, remove the jumper from JM1,install it on JM2, and readjust R1.

(b) If potentiometer R1 is turned all theway down and the voltage is stilltoo high, remove the jumper fromJM2, install it on JM1, and readjustR1.

(c) If VLAMP is between +3.0 and +4.0VDC, no adjustment is needed. Toadjust VLAMP, remove thumbscrew(2, Figure 5-2) and cover plate (1).Loosen the screw on the LCW2mounting block (Figure 7-6). Usethe cover plate to cover the part ofthe optical mounting channel in or-der to block excess light fromreaching the detector. Move theslider that opens and closes the iristo adjust VLAMP to +4.0 ±0.1 Vdc.Then, tighten the mounting blockscrew and install the cover plateand thumbscrew.

4. Recalibrate the opacity transmitter perparagraph 3-7b.

Figure 7-6. VLAMP Adjustment

5. Install electronics housing (14, Figure5-2).

6. Install optical assembly (1, Figure 5-1)in the transceiver module per para-graph 7-3a2.

e. Beam Splitter Alignment

NOTEThe beam splitter is aligned at the fac-tory and should not require adjust-ment. However, it is possible thatreplacing the detector/amplifier boardor loosening the beam splitter mount-ing hardware could result in mis-alignment, causing higher opacityreadings.

1. Set the transceiver and retroreflectormodules on stands in a clean environ-ment as described in paragraph 7-3b.

2. Remove thumbscrew (2, Figure 7-5)and cover plate (1).

3. Remove detector/amplifier board (14)as described in paragraph 7-3c.

4. Place a piece of translucent material,such as thin paper, over the detectorhole in the optical unit.

5. Loosen screws (9).

6. Place the transceiver in the check op-tics mode per paragraph 4-1c.

7. Select the VSTACK setting.

NOTEThe spot of light reflected by the beamsplitter should be visible on thetranslucent material.

8. Adjust beam splitter (10) until the spotof light is centered in the detector hole.

9. Exit the check optics mode.

10. Carefully tighten screws (9), ensuringthe beam remains centered.



Model OPM 2001

11. Install detector/amplifier board (14).

12. Calibrate the opacity transmitter ac-cording to paragraph 3-7b.

13. Recalibrate the zero jig per paragraph7-4a.

f. Liquid Crystal Window Replacement(Refer to Figure 7-5)

1. Remove thumbscrew (2) and coverplate (1).

2. Remove plug-in connector (8 or 20)from the defective LCW.

3. Remove screws (7) and o-rings (3) se-curing the defective LCW.

NOTEWhen removing LCW 1 and apertures orremoving LCW 2, aperture, and reflec-tor, remember the order in which theywere installed. These components mustbe replaced in the same order.

4. If LCW 1 (5) is defective, remove LCW1 and apertures (4 and 6). If LCW 2(18) is defective, remove LCW 2, re-flector (17), and aperture (19).

5. Install the new LCW 1 and apertures orLCW 2, aperture, and reflector and se-cure with o-rings (3) and screws (7).Ensure the components are installed inthe same order they were removed.

6. Reconnect plug-in connector (8 or 20)to the new LCW.

7. Install cover plate (1) and secure withthumbscrew (2).

g. Stack LON Board Replacement

1. Remove optical assembly (1, Figure 5-1) from the transceiver module perparagraph 7-3a1.

2. Remove electronics housing (14, Fig-ure 5-2) by releasing the four toggleclamps that hold it to mounting plate(27).

3. Tag and remove all cables connectedto stack LON board (50).

4. Remove screws (51) and internal starwashers (52) securing stack LONboard (50) to optical mounting channel(22).

5. Remove and replace stack LON board(50).

6. Install internal star washers (52) andscrews (51) to secure stack LON board(50) to optical mounting channel (22).

7. Install all cables removed in step 3.


9. Install optical assembly (1, Figure 5-1)per paragraph 7-3a2.

h. Lamp Power Supply Board Replacement

1. Remove optical assembly (1, Figure5-1) per paragraph 7-3a1.


3. Tag and remove all cables connectedto lamp power supply board (69).

4. Remove screws and washers securinglamp power supply board (69) to opti-cal mounting channel (22).

5. Replace the power supply board. Se-cure board to optical mounting channelwith screws and washers removed instep 4.

6. Install all cables removed in step 3.

7. Install the electronics housing (14).

8. Install the optical assembly per para-graph 7-3a2.


July 2001


Model OPM 2001

7-4 ZERO JIGa. Recalibration Procedure

The zero jig must be adjusted to provide thesame zero response as the opacity trans-mitters simulated zero. A zero jig is specificonly to the individual transmitter to which ithas been calibrated. Make sure the serialnumbers of the zero jig and transmittermatch.

NOTEThe primary zero alignment of theopacity transmitter must be performedunder conditions in which the opticalpath is clear.

1. Set up the opacity transmitter for aclear path condition by either of thefollowing methods.

(a) Ensure the monitored emissionprocess is not in operation and thatthe monitored pathlength is free ofparticulate.

(b) Remove the opacity transmitterfrom the installation and set thetransmitter up under clear pathconditions. Refer to paragraph 3-7b1 steps (a) through (f).

2. Ensure the opacity transmitter is set upto monitor the correct pathlength.

3. Ensure the opacity transmitter is opti-cally aligned. Refer to Section 4.

4. Record the opacity transmitters re-sponse (in percent opacity) to the clearpath condition.

5. Insert the zero jig on the transceiver.

(a) Remove the window access plateand gasket from the transceiver.

(b) Remove the keepers from the zerojig magnets and place the zero jigthrough the window access area.Slide the jig on the window flangeand onto the locating pin.

(c) Slightly rotate the jig back and forthuntil the 2 in. (50.8 mm) diameter

raised section falls into place. Thelocator pin and the two permanentmagnets hold the jig in position.

NOTEIf the opacity transmitter needs to becalibrated, refer to paragraph 3-7b be-fore proceeding with step 6.

6. Record the response to the transmit-ters simulated zero condition as per-cent opacity corrected to stack exitconditions.

Be careful when tightening the coarseadjustment lock screw. Overtighteningthe screw will deform the iris.

7. If necessary, adjust the zero jig to ob-tain the same response as the clearpath condition (0% opacity). Loosenthe coarse adjustment lock screw (Fig-ure 7-7) to adjust the zero jig. Aftermaking the coarse adjustment, tightenthe coarse adjustment lock screw tolock it in place.

Figure 7-7. Zero Jig Adjustmentand Locking Screws



Model OPM 2001

8. To make a finer zero jig adjustment,remove the fine adjustment lock screw.Use the inside fine adjustment screw toobtain the same response as the clearpath condition (0% opacity).

9. After making the adjustment, lock thecalibrated setting in place by insertingthe fine adjustment lock screw.

The zero jig is a sensitive, calibratedinstrument. Store the jig in its protec-tive case when not in use. Failure toproperly store the jig can lead to dam-age or an out-of-calibration condition.

10. Place the keepers on the zero jig mag-nets and return the zero jig to its pro-tective case.

11. If the opacity transmitter was removedin step 1, reinstall the transmitter.

12. Return the system to operation.

b. Calibrated Zero Jig Application

A calibrated zero jig with its locked setting isspecific only to the opacity transmitter towhich the jig was calibrated. The calibratedzero jig can be used to re-zero and re-spanthe specific transmitter without removing thetransmitter from the stack and with theemission process running.

7-5 FUSE REPLACEMENT

a. Transceiver Module - 60 V Power Supply2 (PS2) Fuse F1



3. Remove and replace fuse F1. Selectthe replacement fuse based on thefollowing specifications and linevoltages:

(a) 0.1 A, 250 VAC, Slo Blo, CSA-approved fuse for 100 and 115VAC line voltage

(b) 0.063 A, 250 VAC, Slo Blo, CSA-approved fuse for 220 and 240VAC line voltage

4. Install electronics housing (14) tomounting plate (27).


b. Transceiver Module - 5 V, ±15 V PowerSupply 1 (PS1) Fuse F2



3. Remove and replace fuse F2. Selectthe replacement fuse based on thefollowing specifications and linevoltages:






July 2001


Model OPM 2001

c. Transceiver Module - Heater Fuse F3



3. Remove and replace fuse F3. Selectthe replacement fuse based on thefollowing specifications and line volt-ages:





d. Transceiver Module - Stack TerminationBoard Fuses F1 and F2

1. Disconnect power to the transceivermodule.

2. Remove weather housing (9, Figure5-1) by releasing four toggle clamps(14) securing it to mounting plate (34).

3. Remove three screws (24) to removetop cover plate (25) to reveal stacktermination board (41).

4. Remove and replace fuses F1 and F2(5 A, 250 VAC, Slo Blo, CSA-approvedfuses).

5. Install top cover plate (25) and securewith three screws (24).

6. Install weather housing (9).

e. Type 4X Intelligent Electronics

1. Disconnect power to the intelligentelectronics.

2. Open enclosure (1, Figure 6-5) cover.

3. Remove screws (14) and top coverplate (15).

4. Remove and replace fuse F1 (5 A,250 VAC, Slo Blo, CSA-approved fuse).

5. Install top cover plate (15, Figure 6-5)and secure with screws (14).

6. Close enclosure (1) cover.



Model OPM 2001


July 2001


Model OPM 2001

SECTION 8TROUBLESHOOTING

Install all protective equipment coversand safety ground leads after trouble-shooting. Failure to replace coversand ground leads could result in seri-ous injury or death.

8-1 GENERAL

This section covers the system mode fault indi-cators generated from system self-diagnosticsand provides a general troubleshooting chartand simple test procedures to correct possiblefault conditions.

8-2 SYSTEM MODE INDICATORS

The OPM 2001 Opacity/ Dust Density Trans-mitter has built-in system diagnostics featuresthat indicate fault conditions. These indicationsappear in the MODE line of the HART commu-nicator online menu. Normal opacity measure-ment functions cannot proceed when a systemstatus alarm is indicated. The following modesindicate a fault condition.

a. CALF

This fault occurs if the last calibration failedfor any of the following voltage conditions:

VSTACK 0 - VLAMP 0> 3.0 VDCVLAMP 0 - VSTACK 0> 3.0 VDCVSTACK 0 - VAMB 0< 0.5 VDCVSTACK 0 - VSTACK 1< 0.75 VDCVLAMP 0 - VDARK 0< 2.0 VDCVSTACK 0 > 4.75 VDCVLAMP 0 > 4.75 VDCVDARK 1 < -0.50 VDC

b. COMF

This fault indicates a communication failurecaused by bad connections, faulty stackLON board microprocessor, or corrupt stackLON board EEPROM.

c. SYSFLT

This fault occurs if there is a lamp failure(VLAMP - VDARK < 1.0 VDC), blower failure,the detector voltage is too high (VLAMP orVSTACK > 4.75 V), or the lamp voltage is toohigh.

d. CALF&SYSFLT

This fault indicates that both a CALF andSYSFLT have occurred independently ofeach other.

8-3 DIAGNOSTICS

The OPM 2001 has a self-diagnostic feature toaid in troubleshooting. Before troubleshooting,access the STATUS submenu of theDIAG/SERVICE menu to find up-to-date,ON/OFF indications of system status and faultconditions that will help direct your trouble-shooting efforts. Refer to Table 8-1 for explana-tions of these indicators.



Model OPM 2001

Table 8-1. Diagnostic Indicators

Menu Item

Fault orStatus

Indication DescriptionSTATUS GROUP 0LON COM Status STATUS ONLON communication problem exists, such as bad connec-

tions or signal path interference.OFFNormal condition.

AO1 DAC Trim STATUS ON4-20 mA signal loop needs to be calibrated.OFFCalibration not needed.

STATUS GROUP 1Blower Failure FAULT ONBlower problem exists.

OFFNormal condition.Chk Optics Mode STATUS ONSystem is in the check optics mode.

OFFNormal condition.TCVR Cal Status STATUS ONTransceiver needs to be calibrated.

OFFCalibration is not needed.Dter V too High FAULT ONMeasured voltage readings are > 4.75 V.

OFFNormal condition.Lamp Status STATUS ONLamp problem exists.

OFFNormal condition.STATUS GROUP 2Heater Status STATUS ONHeater is ON.

OFFHeater is OFF.Purge Air Flow Switch#1 (PR SW #1) Fault

FAULT ONProblem exists with blower on transceiver.OFFNormal condition.

Lighted PushbuttonPressed

FAULT ONPushbutton either pressed or faulty.OFFNormal condition.

Purge Air Flow Switch#2 (PR SW #2) Fault

FAULT ONProblem exists with blower on retroreflector.OFFNormal condition.

VLAMP too High FAULT ONLamp voltage is too high.OFFNormal condition.

DIG IN Status STATUS ONDigital input is closed (on).OFFNormal condition.

STATUS GROUP 3Relays 1 through 6 STATUS Indicates the ON or OFF status of each relay. Check the RELAY

CONFIG submenu in the DETAILED SETUP menu for the currentconfiguration of each relay.

AO SATURATEDAO1 through AO3 FAULT ONSpecified analog output is > 20 mA.

OFFNormal condition.AO FIXEDAO1 through AO3 STATUS ONSystem is performing a TRIM DAC or LOOP test on the in-

dicated analog output and the system is in the FIXED MA mode.OFFNormal condition.


July 2001


Model OPM 2001

Table 8-2. Troubleshooting Chart

Alarm, or otherIndication Possible Cause Corrective Action

1. CALF OPM 2001 failed last calibration Recalibrate OPM 2001.2. COMF Failed communications cable Check wiring and connections between intel-

ligent electronics and transceiver.COMF and stack LONboard status LED on

Failed microprocessor Replace stack LON board per paragraph7-3g.

COMF and stack LONboard status LEDblinking

EEPROM missing or damaged Install new EEPROM.

3. SYSFLTBlower failure Plugged purge air filter Check filters on bottom of weather housing

and at blower intake. Clean per paragraph7-2d and 7-2e, if necessary.

Faulty check valve Repair or replace check valve.Faulty sensor tubing from airlens to purge air failure flowswitch

Ensure sensor tube connections are airtight.Check for kinks, cracks, and punctures in theline. Repair or replace sensor tubes asneeded.

Failed purge air flow switch Check that wires are properly connected.Check blowers and air system. Replace flowswitch, if necessary.

Blower failure Inspect blower motor and repair or replace, ifnecessary. Check circuit breaker to blowermotor. Reset circuit breaker as necessary.

Detector voltage toohigh (VLAMP or VSTACK> 4.75 V)

Faulty detector board Adjust detector amplifier potentiometer perparagraph 7-3d. Perform detector test proce-dure per paragraph 8-4a. Repair or replaceas indicated.

Faulty power supply Perform power supply test procedure perparagraph 8-4b. Repair or replace faultypower supply.

Lamp failure (VLAMP -VDARK < 1.0 VDC)

Defective lamp Replace lamp per paragraph 7-3b.

Blown LCW/lamp fuse Replace fuse per paragraph 7-5.Lamp voltage too high or too low(alarmed at 4.6 VDC)

Check voltage to lamp. Replace power sup-ply if necessary.

LCWs #1 and #2 not activatingproperly

Perform LCW test procedure per paragraph8-4c. Replace LCW(s) per paragraph 7-3f, ifnecessary.

Faulty electrical connection be-tween detector/amplifier boardand analog-to-digital converter

Check electrical cable and connection. Re-pair or replace as necessary.

Faulty analog-to-digital converteron stack LON board

Replace stack LON board per paragraph7-3g.



Model OPM 2001

Table 8-2. Troubleshooting Chart (Continued)Alarm, or other

Indication Possible Cause Corrective Action3. SYSFLT (Continued)

Lamp voltage too high Lamp voltage too high (alarmedat 4.6 VDC)

Check voltage to lamp. Replace power sup-ply if necessary.

CAL/CHECK push-button pressed

Pushbutton pressed or faulty(becomes shorted)

Replace if defective.

4. CALF&SYSFLT Calibration failure and a systemfault occurred

Refer to the possible causes and correctiveactions in this table for both CALF andSYSFLT to correct the fault condition.

5. All voltages from de-tector low or the same

Blown detector/amplifier fuse Replace fuse per paragraph 7-5.

Blown LCW/lamp fuse Replace fuse per paragraph 7-5.Faulty detector board Readjust detector amplifier potentiometer per

paragraph 7-3d. Perform detector test proce-dure per paragraph 8-4a. Repair or replaceas required.

Faulty power supply Perform power supply test procedure perparagraph 8-4b. Repair or replace asrequired.

6. Voltage readings toohigh or too low

Gain out of adjustment Adjust detector amplifier potential per para-graph 7-3d.

7. Heater malfunction Blown heater fuse Replace fuse per paragraph 7-5.Burned out or shorted heater Replace heater.Faulty temperature sensor Replace entire stack LON board per paragraph

7-3g.Faulty heater control module Replace heater control module (U12).

8. Opacity or DustReading High

Dirty optics Clean the lens, windows, and corner cubeper paragraph 7-2b. Verify air lens functionsproperly. Repair if necessary.

Condensation on optics Clean the lens, windows, and corner cube.Check the heater and heater circuit. Using anAC voltmeter, verify the line voltage acrossthe TO HEATER terminals on the stack LONboard. Replace the heater if necessary.

Closed or partially closed air lensseal plate

Slide seal plate to fully open position. Ensureseal plate remains open unless manuallyclosed.

OPM out of alignment Check mounting rigidity. Reinstall and tightenmounting hardware as required. Perform op-tical alignment of transceiver and retrore-flector per Section 4.


July 2001


Model OPM 2001

Table 8-2. Troubleshooting Chart (Continued)Alarm, or other

Indication Possible Cause Corrective Action8. Opacity or Dust

Reading High(Continued)

OPM out of calibration

LCW failure

Recalibrate OPM offline or under clearstack conditions per paragraph 3-7b.

Perform LCW test procedure per paragraph8-4c. Replace LCW(s) per paragraph 7-3f asnecessary.

9. Opacity Low or Nega-tive

Online mis-calibration with par-ticulate present

Recalibrate offline or under clear stackconditions per paragraph 3-7b.

OPM 2001 out of alignment Check OPM alignment. If necessary, realignthe OPM 2001 per Section 4.

Insufficient time for system tostabilize after CHECK OPTICSprocedure

Wait at least 30 minutes after CHECK OP-TICS procedure before performing the offlinecalibration.

Faulty LCW 2 (multi-sectoredLCW)

Perform LCW test procedure per paragraph8-4c. Replace LCW 2 per paragraph 7-3f, ifnecessary.

NOTEOpacity 105% indicates a faultother than blower failure.

10. Opacity 105% High voltages (>4.75 VDC) fromdetector/amplifier board saturat-ing the analog-to-digital con-verter, causing high voltagereadings

Check FLD DEVICE VOLTS submenu underPROCESS VARIABLES menu to access lastdetector voltage readings. Perform detectortest procedure per paragraph 8-4a. Make re-pairs as needed.

Communication error due to badsignal cable, bad connections, orsignal interference

Check signal cable for damage and bad con-nections. Repair as necessary. Ensure thesignal path is clear of high voltage lines,transformers, electric motors, and radio fre-quency transmitters. Reroute the signal pathif required.

System out of calibration Calibrate OPM 2001 per paragraph 3-7b.

11. Pushbutton pressed CAL/CHECK pushbutton pressedor faulty

Replace switch if defective.

12. Stack LON boardstatus LED blinking oron steady

Missing stack LON board soft-ware chip or bad stack LONboard

Install stack LON board software chip(1A99073G01) or replace stack LON board.



Model OPM 2001

8-4 TEST PROCEDURES

Death or serious injury is possiblewhen working near exposed electricalterminals and power supplies. Useproper safety precautions whenworking near live lines and terminals.

a. Detector Test Procedure

The detector/ amplifier board outputs onevoltage reading every second during theRUN mode. Abnormal voltages may helpdetermine a problem in the light path. Adigital voltmeter can be used to measurethe voltages in succession. Typical valuesare as follows:

VDARK = +0.2 VDCVLAMP = +4.0 VDCVAMB = +0.7 VDCVSTACK = +1.8 VDC

Check the voltage readings at the signalexit from the left side of R4 on the detec-tor/amplifier board (Figure 7-4). If neces-sary, adjust amplifier gain by adjusting

potentiometer R1. If the output signal volt-ages are not acceptable, perform the powersupply test procedure for power supply 2(PS2) per paragraph 8-4.b.2.

b. PS1 and PS2 Power Supply Test Proce-dures

The stack LON board (Figure 5-11) containstwo power supplies, PS1 and PS2. PS1supplies +5 VDC and ±15 VDC. PS2 sup-plies the LCW driver chip (U6) with 60 VDC.Refer to Figures 5-11 and 8-1 and test PS1and PS2 with a digital voltmeter as follows:

1. Power Supply 1 (PS1). Test PS1 usingthe test points as follows:

TP15 +5 VDC referenced to TP1TP16 -5 VDC referenced to TP1TP13 +5 VDC referenced to TP2TP2 Digital GroundTP9 +15 VDC referenced to TP1TP1 Analog GroundTP11 -15 VDC referenced to TP1

2. Power Supply 2 (PS2). Test PS2 usingthe test points as follows:

TP12 +60 VDC referenced to TP2

Figure 8-1. PS1 and PS2 Test Points


July 2001


Model OPM 2001

c. LCW Test Procedure

Alternating current causes LCWs to changefrom translucent to transparent. The differ-ence can usually be seen by observing theLCWs in the optic channel. Test LCW 1 andLCW 2 as follows:

Death or serious injury is possiblewhen working near exposed electricalterminals and power supplies. Useproper safety precautions whenworking near live lines and terminals.

LCWs will be damaged by direct cur-rent. Do not test LCWs for resistancewith a digital voltmeter. Avoid shortingthe leads at the LCW cableconnectors.

1. Check light path voltages per para-graph 8-4a. If the voltages are signifi-cantly different, replace the leasttransparent LCW.

2. Being careful to avoid shorting theleads, check the voltage entering theLCWs.

3. If the 60 V square wave at 100 Hz ispresent, the LCW should change fromtranslucent to transparent. Replace theLCW if defective per paragraph 7-3f.

4. If 60 V is not present at the LCW, per-form the PS2 test procedure per para-graph 8-4b2.

5. If the problem persists, replace thestack LON board.



Model OPM 2001


July 2001


Model OPM 2001

SECTION 9RETURN OF MATERIAL

9-1 If factory repair of defective equipment is re-quired, proceed as follows:

a. Secure a return authorization from a Rose-mount Analytical Inc. Sales Office or Repre-sentative before returning the equipment.Equipment must be returned with completeidentification in accordance with Rosemountinstructions or it will not be accepted.

In no event will Rosemount be responsiblefor equipment returned without properauthorization and identification.

b. Carefully pack the defective unit in a sturdybox with sufficient shock absorbing materialto ensure no additional damage occursduring shipping.

c. In a cover letter, describe completely:

1. The symptoms that determined theequipment is faulty.

2. The environment in which the equip-ment was operating (housing, weather,vibration, dust, etc.).

3. Site from where the equipment wasremoved.

4. Whether warranty or nonwarrantyservice is expected.

5. Complete shipping instructions for thereturn of the equipment.

d. Enclose a cover letter and purchase orderand ship the defective equipment accordingto instructions provided in the RosemountReturn Authorization, prepaid, to:

Rosemount Analytical Inc.RMR Department1201 N. Main StreetOrrville, Ohio 44667

If warranty service is expected, the defec-tive unit will be carefully inspected andtested at the factory. If the failure was dueto the conditions listed in the standardRosemount warranty, the defective unit willbe repaired or replaced at Rosemounts op-tion, and an operating unit will be returnedto the customer in accordance with theshipping instructions furnished in the coverletter.

For equipment no longer under warranty,the equipment will be repaired at the factoryand returned as directed by the purchaseorder and shipping instructions.



Model OPM 2001


July 2001


Model OPM 2001

SECTION 10REPLACEMENT PARTS



Model OPM 2001

TEST CABLELON TEST CABLELON TEST CABLEINSTRUCTION BULLETININSTALLATION INSTRUCTIONS

TRANSCEIVER MOUNTING PLATE110/115V220/240V

REFLECTOR MTG PLATEWEATHER HOUSINGTRANSCEIVER

100V115V220V240V

OPM 2001 –

4844B57G014844B57G024850B52G01IB-106-20013D39747

0 0 1 1 1 2 1 3 1 4

1

12

1

1111

1

12

1

1

111

112

1

1111

112

1

1111

TRANSCEIVER VOLTAGE

3D39703G013D39703G023D39369G013D39367G01

3D39858G023D39858G033D39858G043D39858G05

DECODE MATRIX

OPM 2001 –

BASIC UNIT (IN BLACK BOX)751 INDICATOR275 HART COMMUNICATOR115VAC/TYPE 4X ENCLOSURE W/P.S.220VAC/TYPE 4X ENCLOSURE W/P.S.115VAC/TYPE 4X ENCL. W/P.S. & HTR.220VAC/TYPE 4X ENCL. W/P.S. & HTR.115VAC/24VDC POWER SUPPLY220VAC/24VDC POWER SUPPLY

3D39705G011A98827H02275R1EI6B3D39704G01

4850B42G014850B42G02

3D39704G023D39704G033D39704G04

0 0 1 0

1

1 1

1

1 1

1 2

1

1

INTELLIGENT ELECTRONICS & OPTIONS

11

2 0

11

2 11 3

1

1 4

1

1 5

1

1 6

1

OPM 2001 –


3D39705G011A98827H02275R1EI6B3D39704G01

4850B42G014850B42G02

3D39704G023D39704G033D39704G04

2 2 2 3

1

1

1

2 4

11

1

2 5

1 1

1


1

1

1

1

1

3 3

1

1

1

1

1

11

3 42 6

1

3 0

1

3 1 3 2

OPM 2001 –


3D39705G011A98827H02275R1EI6B3D39704G01

4850B42G014850B42G02

3D39704G023D39704G033D39704G04

3 5 3 6

1

4 0

1 1 1 1

1

4 1

1 1

1


1

11111

1

1

1

1

1

1

4 6

1

1

1

11

4 2 4 3

1

4 4 4 5


July 2001


Model OPM 2001



Model OPM 2001

Table 10-1. Replacement Parts for General Purpose Intelligent Electronics

Figure andIndex Number Part Number Description

6-1, 66-1, 156-1, 96-1, 16-1, 26-1, 10

1A99043G013D39650G011A99032H031A99032H021A99032H011A99032H04

IG-1 Software BoardHART Daughter Board6-Pin Plug4-Pin Plug3-Pin Plug9-Pin Plug

Table 10-2. Replacement Parts for Type 4X Intelligent Electronics


6-5, 156-5, 196-5, 96-5, 56-5, 76-5, 176-5, 186-5, 86-5, 21

3D39706G011A99043G013D39650G014850B34G011A99032H051A99032H061A99032H071A99032H041A98376H02

Top Cover PlateIG-1 Software BoardHART Daughter BoardTermination Board6-Pin Plug4-Pin Plug3-Pin Plug9-Pin PlugPower Supply (24 VDC)

Table 10-3. Replacement Parts for Transceiver and Retroreflector Modules


5-1, 95-1, 185-1, 205-1, 215-1, 545-1, 535-1, 55-1, 45 through 495-1, 465-1, 585-1, 61

3D39367G014843B11H014843B09H024843B09H011A98502H014842B51G024511C83H019884A16H049884A16H059695D79G063532B51H01

Weather HousingFilter RetainerFilter (Coarse)Filter (Fine)Purge Air Failure Flow SwitchPurge Air Failure Flow Switch Cable (Specify Length)Blower MotorFilter Assembly for BlowerFilter ElementAir Lens AssemblyCheck Valve


July 2001


Model OPM 2001

Table 10-4. Replacement Parts for Transceiver Module


5-15-15-15-15-1, 345-2, 505-2, 505-2, 505-2, 505-2, 565-2, 215-2, 215-2, 675-2, 673-73-72-9, 2-105-2, 345-2, 155-2, 165-2, 175-2, 95-2, 635-2, 635-2, 695-2, 3 through

5, 12, 13

3D39702G023D39702G033D39702G043D39702G053D39385G013D39700G013D39700G023D39700G033D39700G043D39317G014846B44G014846B44G024841B54H014841B54H023D39343G013D39343G023D39664G013D39381G011A99563H014852B28G014841B40H014848B50G024848B50G014848B50G031A99436H014841B10G01

Transceiver Assembly (100V)Transceiver Assembly (115V)Transceiver Assembly (220V)Transceiver Assembly (240V)Transceiver Mounting PlateStack LON Board (100V)Stack LON Board (115V)Stack LON Board (220V)Stack LON Board (240V)Detector/Amplifier BoardHeater (110/115V)Heater (220/240V)Objective Lens, 3 to 10 ft (0.915 to 3.05 m)Objective Lens, 10 to 26 ft (3.05 to 7.9 m)Zero Jig, 3 to 20 ft (0.915 to 6.1 m)Zero Jig, 20 to 26 ft (6.1 to 7.9 m)Stack Termination BoardWindow Flange (With Zero Jig Locating Pin)Lamp Mounting AdapterLamp AssemblyLamp HolderLCW 1LCW 2, 3 to 10 ft (0.915 to 3.05 m)LCW 2, 10 to 26 ft (3.05 to 7.9 m)Lamp Power Supply BoardBeam Splitter Assembly

Table 10-5. Replacement Parts for Retroreflector Module


4-14-15-12, 25-12, 25-12, 24-1

3D39369G013D39369G024846B93G014846B93G024846B93G034842B21G01

Retroreflector Mounting Plate (110/115V)Retroreflector Mounting Plate (220/240V)Retroreflector, 3 to 10 ft (0.915 to 3.05 m)Retroreflector, 10 to 20 ft (3.05 to 6.1 m)Retroreflector, 20 to 26 ft (6.1 to 7.9 m)Alignment Sight Assembly



Model OPM 2001

Table 10-6. Replacement Parts Kit

Figureand IndexNumber Location

PartNumber Description

QtyinKit

1A98248G02 OPM 2001 Spare Parts Kit. Includes thefollowing:

5-11 60 V Power Supply (PS2) FuseF1 for 100/115 VAC System

1A97913H12 Fuse, Slo Blo, 0.1A @ 250 VAC,Case Size: 5 x 20 mm,Cooper Bussman Part No. GMC-100mA

5

5-11 60 V Power Supply (PS2) FuseF1 for 220/240 VAC System

1A97913H17 Fuse, Slo Blo, 0.063 A @ 250 VAC,Case Size: 5 x 20 mm,Cooper Bussman Part No. GMC-63mA

5

5-11 5 V, ±15 V Power Supply (PS1)Fuse F2 for 100/115 VAC Sys-tem

1A97913H10 Fuse, Slo Blo, 0.25A @ 250 VAC,Case Size: 5 x 20 mm,Cooper Bussman Part No. GMC-250mA

5

5-11 5 V, ±15 V Power Supply (PS1)Fuse F2 for 220/240 VAC Sys-tem

1A97913H09 Fuse, Slo Blo, 0.125 A @ 250 VAC,Case Size: 5 x 20 mm,Cooper Bussman Part No. GMC-125mA

5

2-9, 2-10,5-11, and6-6

Heater Fuse F3 for 100/115VAC System, Stack TerminationFuses F1 and F2, and NEMA 4XIntelligent Electronics Fuse F1

1A97913H03 Fuse, Slo Blo, 5 A @ 250 VAC,Case Size: 5 x 20 mm,Schurter Part No. FST 034.3124

10

5-11 Heater Fuse F3 for 220/240VAC System

1A97913H16 Fuse, Slo Blo, 2.5A @ 250 VAC,Case Size: 5 x 20 mm,Cooper Bussman Part No. GMC-2.5A

5

5-1, 21 Filter Housing 4843B09H01 Filter, Fine 4

5-1, 20 Filter Housing 4843B09H02 Filter, Coarse 4

Table 10-7. Certified Neutral Density Filters

4846B98

Group

FilterDesignation Part Number G01 G02 G03 G04 G05 G06 G07

3% - #5038% - #508

20% - #52037% - #53750% - #55060% - #56075% - #57580% - #50888% - #588

4846B98H014846B98H024846B98H034846B98H044846B98H054846B98H064846B98H074846B98H084846B98H09

111 1

11

1

11

1

111

1

1

1

1

1

111


July 2001


Model OPM 2001

SECTION 11APPENDICES

APPENDIX AThe following table shows the relationship be-tween percent opacity (Op), percent transmis-sion (Tr), and optical density (OD). Use this

chart when performing the EPA filter check pro-cedure in paragraph 3-7g.



Model OPM 2001

Op Tr Density Op Tr Density Op Tr Density0.0 100.0 0.0000 4.7 95.3 0.0209 9.4 90.6 0.04290.1 99.9 0.0004 4.8 95.2 0.0214 9.5 90.5 0.04340.2 99.8 0.0009 4.9 95.1 0.0218 9.6 90.4 0.04380.3 99.7 0.0013 5.0 95.0 0.0223 9.7 90.3 0.04430.4 99.6 0.0017 5.1 94.9 0.0227 9.8 90.2 0.04480.5 99.5 0.0022 5.2 94.8 0.0232 9.9 90.1 0.04530.6 99.4 0.0026 5.3 94.7 0.0237 10.0 90.0 0.04580.7 99.3 0.0031 5.4 94.6 0.0241 10.1 89.9 0.04620.8 99.2 0.0035 5.5 94.5 0.0246 10.2 89.8 0.04670.9 99.1 0.0039 5.6 94.4 0.0250 10.3 89.7 0.04721.0 99.0 0.0044 5.7 94.3 0.0255 10.4 89.6 0.04771.1 98.9 0.0048 5.8 94.2 0.0259 10.5 89.5 0.04821.2 98.8 0.0052 5.9 94.1 0.0264 10.6 89.4 0.04871.3 98.7 0.0057 6.0 94.0 0.0269 10.7 89.3 0.04911.4 98.6 0.0061 6.1 93.9 0.0273 10.8 89.2 0.04961.5 98.5 0.0066 6.2 93.8 0.0278 10.9 89.1 0.05011.6 98.4 0.0070 6.3 93.7 0.0283 11.0 89.0 0.05061.7 98.3 0.0074 6.4 93.6 0.0287 11.1 88.9 0.05111.8 98.2 0.0079 6.5 93.5 0.0292 11.2 88.8 0.05161.9 98.1 0.0083 6.6 93.4 0.0297 11.3 88.7 0.05212.0 98.0 0.0088 6.7 93.3 0.0301 11.4 88.6 0.05262.1 97.9 0.0092 6.8 93.2 0.0306 11.5 88.5 0.05312.2 97.8 0.0097 6.9 93.1 0.0311 11.6 88.4 0.05352.3 97.7 0.0101 7.0 93.0 0.0315 11.7 88.3 0.05402.4 97.6 0.0106 7.1 92.9 0.0320 11.8 88.2 0.05452.5 97.5 0.0110 7.2 92.8 0.0325 11.9 88.1 0.05502.6 97.4 0.0114 7.3 92.7 0.0329 12.0 88.0 0.05552.7 97.3 0.0119 7.4 92.6 0.0334 12.1 87.9 0.05602.8 97.2 0.0123 7.5 92.5 0.0339 12.2 87.8 0.05652.9 97.1 0.0128 7.6 92.4 0.0343 12.3 87.7 0.05703.0 97.0 0.0132 7.7 92.3 0.0348 12.4 87.6 0.05753.1 96.9 0.0137 7.8 92.2 0.0353 12.5 87.5 0.05803.2 96.8 0.0141 7.9 92.1 0.0357 12.6 87.4 0.05853.3 96.7 0.0146 8.0 92.0 0.0362 12.7 87.3 0.05903.4 96.6 0.0150 8.1 91.9 0.0367 12.8 87.2 0.05953.5 96.5 0.0155 8.2 91.8 0.0372 12.9 87.1 0.06003.6 96.4 0.0159 8.3 91.7 0.0376 13.0 87.0 0.06053.7 96.3 0.0164 8.4 91.6 0.0381 13.1 86.9 0.06103.8 96.2 0.0168 8.5 91.5 0.0386 13.2 86.8 0.06153.9 96.1 0.0173 8.6 91.4 0.0391 13.3 86.7 0.06204.0 96.0 0.0177 8.7 91.3 0.0395 13.4 86.6 0.06254.1 95.9 0.0182 8.8 91.2 0.0400 13.5 86.5 0.06304.2 95.8 0.0186 8.9 91.1 0.0405 13.6 86.4 0.06354.3 95.7 0.0191 9.0 91.0 0.0410 13.7 86.3 0.06404.4 95.6 0.0195 9.1 90.9 0.0414 13.8 86.2 0.06454.5 95.5 0.0200 9.2 90.8 0.0419 13.9 86.1 0.06504.6 95.4 0.0205 9.3 90.7 0.0424 14.0 86.0 0.0655


July 2001


Model OPM 2001




Model OPM 2001



July 2001


Model OPM 2001




Model OPM 2001



July 2001


Model OPM 2001




Model OPM 2001



July 2001


Model OPM 2001

Op Tr Density Op Tr Density Op Tr Density98.7 1.3 1.8861 99.2 0.8 2.0969 99.6 0.4 2.397998.8 1.2 1.9208 99.3 0.7 2.1549 99.7 0.3 2.522998.9 1.1 1.9586 99.4 0.6 2.2218 99.8 0.2 2.699099.0 1.0 2.0000 99.5 0.5 2.3010 99.9 0.1 3.000099.1 0.9 2.0458



Model OPM 2001


July 2001


Model OPM 2001

APPENDIX BThe following chart is the preventivemaintenance schedule for ensuringmaximum uptime of your OPM 2001Opacity Transmitter. The checklist isto serve as a guideline for performingpreventive maintenance. At a mini-

mum, perform all maintenance at thespecified intervals. Certain situationsmay require more frequent checksand service. Refer to Sections 3 and 7for calibration, disassembly, assem-bly, and replacement procedures.

OPM 2001 Service Schedule A - Quartely AuditC - CleanT - Return for Re-Certification

I - Inspect (After inspection, clean, lubricate, adjust or replace if necessary)

R - Replace

Months 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Air Lens Assembly C C C C

Air Lens Seal Plate I I I I

Align Optics I I I I

Beam Splitter I I I I

Blowers I I I I I I I I

Check Valve I I I I

Corner Cube Retroreflector C C C C C C C C

Detector/Amplifier Board I I I I

Lamp Power Supply Board I I I I

Epa Audit/Filter Check A A A A A A A A A A A A A A A A% Filter Elements Internal C C C C C C C R

% Filters Fine, Coarse, External C C C C C C C R C C C C C C C R

Heater (Optical Bench) I I I I

Intelligent Electronics

Internal Retroreflector I I I I

Lamp Replacement R R R R R R R R

Liquid Crystal Windows I I

Neutral Density Filters T T T T

Objective Lens I C I C

Offline Calibrate I I I I

Optical Alignment I I I I

Transceiver Power Supply 1 I I I I

Transceiver Power Supply 2 I I I I

Transceiver Stack Lon Board I I I I

Purge Air Failure Flow Switch I I I I

Transceiver Window C C C C C C C C

Weather Housing I I I I

Zero Jig I I I I

Zero And Span Check

% Under severe ambient conditions, service these items more frequently.



Model OPM 2001


July 2001


Model OPM 2001

APPENDIX CUse this worksheet to record and reference the settings of your OPM 2001 system.

ROSEMOUNT OPACITY VALUES WORKSHEETUnit Serial Number: _______________P.O. Number: _______________Date: _______________

Menu Access Parameter ReadingFld Device Volts VstackProcess

Variables VlampVambVdarkStack Temperature Vad 590

TempOutput Variables PV Output Vars PV is

Opacity Value% RngePV AO (Opacity Output)

SV Output Vars SV isOpacity Value% RngeSV AO (Opacity Output)

TV Output Vars TV isOpacity Value% RngeTV AO (Opacity Output)

Variable Mapping Variable MappingVariable Re-map Variable Re-map MethodStatus Status Group 0 LON COM StatusDiagnostic/

Service AO1 DAC TrimStatus Group 1 Blower Failure

Chk Optics ModeTCVR Cal StatusDter too HighLamp Status

Status Group 2 Heater StatusPR SW #1 StatusLP Button StatusPR SW #2 StatusVlamp too HighDIG IN Status



Model OPM 2001

Menu Access Parameter ReadingStatus (Cont.) Status Group 3 Relay 1

Relay 2Diagnostic/Service(Cont.) Relay 3

Relay 4Relay 5Relay 6

AO Saturated AO1AO2AO3

AO Fixed AO1AO2AO3

Offline Cal Offline Cal MethodRef. Voltages CalDate

CalTimeVstack0Vlamp0Vamb0Vdark0Vstack1Vlamp1Vamb1Vdark1OCRF

Trim DAC Trim DAC MethodLoop Test Loop Test PV Loop Test PV Method

Loop Test SV Loop Test SV MethodLoop Test TV Loop Test TV Method

Check Optics Check Optics MethodFltr Chk Filter Check Filter Check Method

Fltr Chk Values Fltr Chk Values MethodErase Fltr Values Erase Fltr Values Method

Setup Clock DateBasicSetup Time

Clock Setup Clock Setup MethodRange Values Select PV Range URV URV Method

LRVSelect SV Range URV URV Method

LRVSelect TV Range URV URV Method

LRV


July 2001


Model OPM 2001

Menu Access Parameter ReadingLX/LT Lx/Lt

LX/LT Setup Lx/Lt Setup MethodDevice Info Dev ID

DescriptorTag

BasicSetup(Cont.)

MessageRelay Config Relay Config Relay Config MethodDetailed

Setup Relay 1Relay 2Relay 3Relay 4Relay 5Relay 6

Zero/Span Check Zero ValZero FltrSpan ValSpan FltrPeriodStartZero DurSpan DurZero/SpanConfiguration

Zero/Span ConfigurationMethod

Averages Average 1 Avg 1 VarAvg 1 Per

Average 2 Avg 2 VarAvg 2 Per

Alarms Alarm Config Alarm Config MethodAlarm 1Alarm 1 TypeAL1 SetpointAL1 DeadbandAlarm 2Alarm 2 TypeAL2 SetpointAL2 Deadband

Dust Setup Dust CDust KDateTimeDust Configuration Dust Configuration Method



Model OPM 2001

Menu Access Parameter ReadingReview IG-1 S/W Version Rev Num

Rev YearRev MonthRev DayRev HourRev Minute

Stack S/W Version Rev NumRev YearRev MonthRev DayRev HourRev Minute

Serial Numbers System SN


July 2001


Model OPM 2001

SECTION 12INDEX

This index is an alphabetized listing of parts, terms, and procedures having to do with the OPM2001 Opacity Transmitter. Every item listed in this index refers to a location in the manual by oneor more page numbers.

-20 mA Loop to Stack Connector, 6-324 VDC Connector, 6-3

AAction Keys, 3-6Address, Rosemount Analytical Inc., 9-1Air Lens, 5-1Air Lens Assembly, 5-9, 5-10Air Lens Assembly - Exploded View, 5-10Air Lens Assembly Specifications, 1-7ALARMS, 3-27ALARMS Sub-menu, 3-27Align the Retroreflector, 4-3Align the Transceiver, 4-2Alignment Sight, 4-3Alphanumeric Keys, 3-6Ambient Mode, 5-4Analog Output Connector, 6-4Averages, 1-8AVERAGES, 3-26AVERAGES Sub-menu, 3-26

BBall Joint, 4-3Ball Joint, Transceiver Module, 4-3BASIC SETUP MENU, 3-19Beam Splitter Adjustment, 7-6Beam Splitter Alignment, 7-7Blower Motor, 2-11, 5-1

CCALF, 8-1CALF&SYSFLT, 8-1Calibrate the Analog Outputs, 3-14Calibrated Zero Jig Application, 7-10Calibrating, 3-11Calibration Curve, 1-6Calibration Dimensions, 1-4Calibration Validity, 3-15Certification, 1-8CHECK OPTICS, 3-15Check Optics Mode, 4-1, 4-4Check the Calibration, 4-3

Clearance Considerations, 2-1COMF, 8-1COMM LED, 6-2COMPONENT CHECKLIST, 1-1Component Relationships, 1-3Cooling Fins, 2-8Corner Cube, 5-8Crosshair Image, 4-3Crosshairs, 4-3Current Carrying Requirements, 2-9Customer Connections, 2-12

DDark Mode, 5-4Default Configuration, 6-4DETAILED SETUP MENU, 3-22Detector, 5-5Detector Circuit, 5-7Detector Test Procedure, 8-6Detector/Amplifier Board, 1-3Detector/Amplifier Board Replacement, 7-5Detector/Amplifier PC Board, 5-5DEVICE INFO, 3-21DEVICE INFO Sub-menu, 3-21Device Setup, HART, 3-7DIAG/SERVICE MENU, 3-10Diagnostic Indicators, 8-2DIAGNOSTICS, 8-1Digital Input Connector, 6-3Dust Concentration, 1-5Dust Concentration Calculation, Graphic

Relationship, 1-6DUST SETUP, 3-28DUST SETUP Sub-menu, 3-28

EElectrical Specifications, 1-7Environmental Specifications, 1-7EPA Filter Placement, 3-16Erase Fltr Values, 3-15External Filters - Exploded View, 7-2Extinction and Dust Measurement, Graphical

Relationship, 1-5



Model OPM 2001

FFailsafe Configuration, 6-4Fault Indicators, 8-1FAULT LED, 6-2Filter Check, 3-15Filter Check Values, 3-17Filters and Zero Jig, 5-5FLD DEVICE VOLTS, 3-7FLD DEVICE VOLTS Sub-menu, 3-8Flow Switch Status, 5-9FLTR CHECK Sub-menu, 3-17FLTR CHK, 3-15FLTR CHK Sub-menu, 3-15Fltr Chk Values, 3-15Focus the Objective Lens, 4-4Function Keys, 3-5FUSE REPLACEMENT, 7-10

GG-1 Software Board, 6-5Gain Adjustment, 5-6General Purpose Intelligent Electronics, 2-11General Purpose Intelligent Electronics - Exploded

View, 6-1Graphical Relationship, 1-4

HHANDLING, 2-3HART Communications, 1-3HART Communicator, 3-1HART COMMUNICATOR MENU TREE, 3-29HART Daughter Board, 2-16, 6-3, 6-5HART INTERFACE, 3-6HART Menu Tree, 3-30HART OPERATOR INTERFACE, 3-4HART SIGNAL LINE CONNECTIONS, 3-1HART Terminal Connections, 3-2Heater, 5-8, 6-7Heat-Resistant Gasket, 2-4High Heat Applications, 2-8HIGH TEMPERATURE APPLICATIONS, 2-7

IIG-1 Software Board, 6-2INSTALLATION, 2-1Installation Guidelines, 2-2Insulation, 2-8Intelligent Electronics, 1-1, 2-4, 6-1INTELLIGENT ELECTRONICS (GENERAL

PURPOSE), 6-1

Intelligent Electronics Mounting Dimensions, 2-6Intelligent Electronics Specifications, 1-7Internal Filter - Exploded View, 7-3Iso-Kinetic Sampling, 1-5

LLamp Light Path, 5-5Lamp Mode, 5-4Lamp Power Supply, 5-8Lamp Power Supply Board Replacement, 7-8Lamp Replacement, 7-4LCD Display, 3-4LCW Locations, 3-8LCW Replacement, 7-6LCW Sector Status, 3-25LCW States, 3-8LCW Test Procedure, 8-7LIFTING, 2-3Light Path Modes, 5-3Light Source, 5-1Liquid Crystal Window Replacement, 7-8Liquid Crystal Windows (LCWs), 3-8, 5-1Locate the Transmitter, 2-2LOCATION, 2-1Location Considerations, 2-1Location, General Purpose Intelligent

Electronics, 2-7Location, Model 751 Indicator, 2-7Location, Type 4X Intelligent Electronics, 2-7LOOP TEST, 3-14LOW AMBIENT TEMPERATURES, 2-9Lower Range Value (LRV), 3-20lt, 1-4lx, 1-4LX/LT, 3-21LX/LT Parameter, 1-4

MMAINTENANCE, 7-1Measurement Cycle, 5-3Measurement Modes, 5-3Measurement Value, 1-4Measuring Opacity, 1-1METHOD OF MEASUREMENT, 1-6Model 751 Indicator Wiring, 2-16MONITORING OPACITY, 2-7, 2-9MOUNTING, 2-2MOUNTING INSTRUCTIONS, 2-4Mounting Plate, 5-1


July 2001


Model OPM 2001

NNeutral Density Filters (NDFs), 3-12Normal Operating Conditions, 6-4Normally Closed Relay, 6-4Normally De-Energized Relay, 6-4Normally Energized Relay, 6-4Normally Open Relay, 6-4

OOBJECTIVE LENS ADJUSTMENT, 4-4, 4-5OFFLINE CAL, 3-11OFFLINE CAL Menu, 3-11Offline Calibration, 3-11OFFLINE OPERATIONS, 3-4ONLINE OPERATIONS, 3-4Opacity, 1-1Opacity and Extinction, 1-5Opacity Data, 1-1OPACITY VALUES WORKSHEET, 11-13Opacity/Dust Density Transmitter, 1-2OPERATION, 3-1Operational Specifications, 1-8OPTICAL ALIGNMENT, 4-1, 4-2Optical Alignment Sight, 4-3Optical Assembly, 5-1Optical Correction Factor (OCRF), 3-12Optical Density, 1-4Optical Enclosure Cover, 7-3Optical Mounting Channel, 5-6Optical System, 5-1Optional Heater Wiring, 2-16Output Variables, 3-9OUTPUT VARIABLES Sub-menu, 3-9

PPhysical Specifications, 1-7POWER LED Lights, 6-2Power Supply, 6-7Power Supply Test Procedures, 8-6PREVENTATIVE MAINTENANCE, 7-1Preventive Maintenance Schedule, 11-11Process Considerations, 2-2PROCESS VARIABLES, 3-7PS1 and PS2 Test Points, 8-6Purge Air, 2-8Purge Air Blower, 4-1PURGE AIR FAILURE FLOW SWITCH, 5-9Purge Air Heater, 2-10Purge Air Heaters, 2-9Purge Air Path, 4-2

RRANGE VALUES, 3-20Real-Time Clock, 6-3Recalibration Procedure, 7-9REF. VOLTAGES, 3-13REF. VOLTAGES Sub-menu, 3-13Reference Value, 1-4Regulatory Considerations, 2-2Relay and Analog Output Connections, 2-16RELAY CONFIG, 3-22RELAY CONFIG Sub-menu, 3-22Relay Contact Connector, 6-3Repair, 7-3Replace Optical Assembly, 7-3REPLACEMENT PARTS, 10-1Retroreflector, 2-11Retroreflector Alignment Nuts, 4-3Retroreflector and Air Lens Assembly, Exploded

View, 5-8Retroreflector Location, 2-2Retroreflector Module, 1-1, 2-11, 5-8Retroreflector Mounting, 2-4Return Authorization, 9-1RETURN OF MATERIAL, 9-1REVIEW MENU, 3-29Ringelmann Numbers, 1-4

SSectored LCW2, 3-23Sectored Liquid Crystal Window (LCW), 3-23SERVICE, 7-1SETUP CLOCK, 3-19SETUP CLOCK Sub-menu, 3-19Shift Keys, 3-6Shutters, 5-1Signal Line Connections, 3-3Sliding Seal Plate, 7-3SPECIFICATIONS, 1-7Spectral Response Curve, 5-6Spectral Response Range, 1-1Stabilizers, 2-4Stack Flange Installation, 2-3STACK FLANGES, 2-2Stack Installation Dimensions, 2-5Stack LON Board, 5-6, 5-7Stack LON Board Replacement, 7-8Stack Mode, 5-3Standard Wiring Practices, 2-9STARTUP PROCEDURE, 1-9Stationary Source Emissions, 1-5



Model OPM 2001

SYSFLT, 8-1System Description, 1-1SYSTEM MODE INDICATORS, 8-1SYSTEM OVERVIEW, 1-1System Status Modes, 3-7SYSTEM WIRING, 2-9

TTermination Board, 5-6, 6-7TEST PROCEDURES, 8-6Thermo Isolators, 2-7TRANSCEIVER AND RETROREFLECTOR

MODULES, 5-1Transceiver and Retroreflector Specifications, 1-7Transceiver Location, 2-2TRANSCEIVER MODULE, 5-1Transceiver Module - Exploded View, 5-0Transceiver Mounting, 2-4Transceiver Optical Assembly - Exploded View, 5-2Transmissometer, 1-2Transmitter/Receiver Module, 1-1TRIM DAC Procedure, 3-14Trimming the Analog Output, 3-14TROUBLESHOOTING, 8-1Troubleshooting Chart, 8-3Type 4X Enclosure, 6-7

TYPE 4X INTELLIGENT ELECTRONICS, 6-5Type 4X Intelligent Electronics - Exploded View, 6-6

UUpper Range Value (URV), 3-20

VVARIABLE MAPPING, 3-10VARIABLE RE-MAP, 3-10VLAMP Adjustment, 7-7

WWarranty Service, 9-1Weather Housing, 5-1Weather Housings, 4-1Wiring Practices, 2-9

ZZero Jig, 3-12, 3-16, 3-17, 7-9Zero Jig Adjustment and Locking, 7-9Zero Jig Calibration, 3-17Zero Jig Mounting, 5-5ZERO/SPAN CHECK, 3-23ZERO/SPAN CHECK Sub-menu, 3-24


July 2001


Model OPM 2001

SECTION 13DRAWINGS AND SCHEMATICS



Model OPM 2001

3556/7-01

ROSEMOUNT WARRANTY

Rosemount warrants that the equipment manufactured and sold by it will, upon shipment, be freeof defects in workmanship or material. Should any failure to conform to this warranty become ap-parent during a period of one year after the date of shipment, Rosemount shall, upon promptwritten notice from the purchaser, correct such nonconformity by repair or replacement, F.O.B.factory of the defective part or parts. Correction in the manner provided above shall constitute afulfillment of all liabilities of Rosemount with respect to the quality of the equipment.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WAR-RANTIES OF QUALITY WHETHER WRITTEN, ORAL, OR IMPLIED (INCLUDING ANYWARRANTY OF MERCHANTABILITY OF FITNESS FOR PURPOSE).

The remedy(ies) provided above shall be purchaser's sole remedy(ies) for any failure ofRosemount to comply with the warranty provisions, whether claims by the purchaser are basedin contract or in tort (including negligence).

Rosemount does not warrant equipment against normal deterioration due to environment. Factorssuch as corrosive gases and solid particulates can be detrimental and can create the need for re-pair or replacement as part of normal wear and tear during the warranty period.

Equipment supplied by Rosemount Analytical Inc. but not manufactured by it will be subject to thesame warranty as is extended to Rosemount by the original manufacturer.

At the time of installation it is important that the required services are supplied to the system andthat the electronic controller is set up at least to the point where it is controlling the sensor heater.This will ensure, that should there be a delay between installation and full commissioning that thesensor being supplied with ac power and reference air will not be subjected to componentdeterioration.


© Rosemount Analytical Inc. 2001

Model OPM 2001

Emerson Process ManagementRosemount Analytical Inc.Process Analytic Division1201 N. Main St.Orrville, OH 44667-0901T (330) 682-9010F (330) 684-4434E [email protected]

ASIA - PACIFICFisher-RosemountSingapore Private Ltd.1 Pandan CrescentSingapore 128461Republic of SingaporeT 65-777-8211F 65-777-0947http://www.processanalytic.com

Fisher-Rosemount GmbH & Co.Industriestrasse 163594 HasselrothGermanyT 49-6055-884 0F 49-6055-884209

EUROPE, MIDDLE EAST, AFRICAFisher-Rosemount Ltd.Heath PlaceBognor RegisWest Sussex PO22 9SHEnglandT 44-1243-863121F 44-1243-845354

LATIN AMERICAFisher - RosemountAv. das Americas3333 sala 1004Rio de Janeiro, RJBrazil 22631-003T 55-21-2431-1882

Model OPM 2001 - · PDF fileHART Menu Tree for the OPM 2001 (Sheet 2 of 3 ... installation...

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