Emerson OPM 3000 User manual

http://www.raihome.com
Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
Opacity/Dust Density Monitor

HIGHLIGHTS OF CHANGES
Effective November 12, 2008 Rev 2.0
Page Summary
Page 1-6 Revised errant OPRL/Exit Correlation equation to read Lx/2Lt.
Page 1-7 Revised final Code text to read Dust Density Calculation, 2 places.
Page 2-1 Revised text of 3rd WARNING from ’power supply’ to ’power source’ for clarity.
Page 2-5 Added introductory paragraph to Mechanical Installation topic.
Page 2-9 Added introductory paragraph to Mounting the Air Plenum topic.
Page 2-11 Added introductory paragraph to Mounting the Transceiver topic.
Page 2-13 Revised major heading to read ’Wiring Installation’. Added introductory paragraph to
Wiring Installation. Added ’Input Connections’ heading for clarity. Revised instruction sets
for remaining three subtopics to better agree with reference wiring diagram, Figure 2-9.
Page 2-14 Revised improperly named heading of Figure 2-9 to read ’Wiring Diagram’. Revised
content of Figure 2-9 to reflect wiring changes applicable to new controller unit. Added
more callouts to wiring diagram for clarity.
Page 2-15 Moved previous topic ’Beam Alignment Procedure’ to Section 3 to allow completion of all
Wiring Installation tasks before commencing beam alignment. Revised ’Output
Connections’ heading and related subtopic headings to reflect correct task breakdown and
clarify contents of ’Wiring Installation’ instruction set. Corrected errant terminals
nomenclature throughout Output Connections instructions; ie: ’02’ corrected to read ’O2’.
Page 3-1 Moved instruction set of previous Overview topic to follow new Startup heading. Revised
and reordered Startup instruction set to reflect a more logical task sequence.
Page 3-2 Revised Stack / Exit heading and structure of related equations shown in step 2.
Page 3-4 Revised text of first heading and follow on paragraph for clarity.
Page 3-5 Revised structure and style of equation shown in step 8.
Page 4-1 Revised Overview to reference mg/m3 version procedures in new Appendix A. Corrected
’perimeters’ to read ’parameters’ throughout section. Revised ’Main Display Screens’
heading to read "Selecting a Display Page" to better reflect topic of discussion. Revised
instruction set to better agree with view in Figure 4-1. Revised title of Figure 4-1 from ’Main
Page’ to ’Opening Page/Screen’ to avoid confusion with the ’Main’ page selected in the
display view. (The Main Page will display when the return button is pushed.)
Page 4-2 Added ’About Page’ heading for clarity.
Page 4-4 Added new Figure 4-6, Setup Page for clarity. Added Note to reference additional setup
parameters discussion in Appendix A.
Page 6-1 Expanded section contents to include component replacement headings. Moved Table 6-1
to page 6-2 to display the full maintenance schedule on a single page.
Page 6-2 through 6-6 Revise layout of text and illustration for instructional clarity.
Appendix A Added new appendix. Renumbered remaining appendices.

Instruction Manual
IM-105-3000, Rev 2.0
November 2008 OPM 3000
http://www.raihome.com
Table of Contents
Essential Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1
Description and
Specifications
Component Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OPM 3000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Normal Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
OPM 3000 - Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SECTION 2
Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Choose an Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sample Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Stack Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Regulatory/Process Considerations . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installation of Stack Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Mounting the Air Plenum and Weather Covers . . . . . . . . . . . . . . . 2-9
Attach Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mounting the Transceiver and Retro Reflector. . . . . . . . . . . . . . . 2-11
Mounting the
Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Input Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
RS485 Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SECTION 3
Startup and Calibration
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Startup Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Beam Alignment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stack / Exit Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Initial Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
On Stack Zero and Span Calibration . . . . . . . . . . . . . . . . . . . . . . . 3-4

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
TOC-2
SECTION 4
Normal Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Selecting a Display Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
About Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Setup of Password Protected parameters . . . . . . . . . . . . . . . . . . . 4-4
Off Stack Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SECTION 5
Zero Jig and Neutral
Density Filter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Zero Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Coarse Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Filter Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Filter Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
SECTION 6
Maintenance
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Corrective Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Transceiver Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
SECTION 7
Troubleshooting
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SECTION 8
Spare Parts
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
OPM 3000 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . 8-1
APPENDIX A
Dust Density Calculation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Correlation with Particulate Density. . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Initial Alignment and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Setup for O.D. Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Example after the Stack Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
mg/m3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
Display and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Setup of Password Protected Parameters . . . . . . . . . . . . . . . . . . .A-9
MODBUS Polling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
APPENDIX B
Safety Data
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
APPENDIX C
Returning Equipment to
the Factory
Returning Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Instruction Manual
IM-105-3000, Rev 2.0
November 2008 OPM 3000
http://www.raihome.com
OPM 3000 Opacity/Dust Density Monitor
ESSENTIAL
INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management designs, manufactures and tests its products
to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install,
use and maintain them to ensure they continue to operate within their
normal specifications. The following instructions MUST be adhered to and
integrated into your safety program when installing, using, and maintaining
Emerson’s Rosemount Analytical products. Failure to follow the proper
instructions may cause any one of the following situations to occur: Loss of
life; personal injury; property damage; damage to this instrument and
warranty invalidation.
•Read all instructions prior to installing, operating and servicing the
product.
• If you do not understand any of the instructions, contact your
Emerson Process Management representative for clarification.
•Follow all warnings, cautions and instructions marked on and
supplied with the product.
•Inform and educate your personnel in the proper installation,
operation and maintenance of the product.
•Install your equipment as specified in the Installation Instructions
of the appropriate Instruction Manual and per applicable local and
national codes.Connect all products to the proper electrical and
pressure sources.
• To ensure proper performance, use qualified personnel to install,
operate, update, program, and maintain the product.
• When replacement parts are required, ensure that qualified people use
replacement parts specified by Emerson Process Management.
Unauthorized parts and procedures can affect the product's
performance, place the safe operation of your process at risk, and
VOID YOUR WARRANTY. Look-alike substitutions may result in fire,
electrical hazards or improper operation.
• Ensure that all equipment doors are closed and protective covers
are in place, except when maintenance is being performed by
qualified persons, to prevent electrical shock and personal injury.
The information contained in this document is subject to change without
notice.

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
ii
PREFACE The purpose of this manual is to provide information concerning the
components, functions, installation and maintenance of the OPM 3000.
Some sections may describe equipment not used in your configuration. The
user should become thoroughly familiar with the operation of this module
before operating it. Read this instruction manual completely.
DEFINITIONS The following definitions apply to WARNINGS, CAUTIONS and NOTES found
throughout this publication.
NOTE
Highlights an essential operating procedure, condition, or statement.
SYMBOLS
NOTE TO USERS
The number in the lower right corner of each illustration in this publication is a
manual illustration number. It is not a part number and is not related to the
illustration in any technical manner.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in injury, death, or long-term health hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition, statement, etc. If not
strictly observed, could result in damage to or destruction of equipment, or loss of
effectiveness.
: EARTH (GROUND) TERMINAL
: PROTECTIVE CONDUCTOR TERMINAL
: RISK OF ELECTRICAL SHOCK
: WARNING: REFER TO INSTRUCTION BULLETI
N

Instruction Manual
IM-105-3000, Rev 2.0
November 2008 OPM 3000
http://www.raihome.com
Section 1 Description and Specifications
Component Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 1-6
OPM 3000 - Ordering Information . . . . . . . . . . . . . . . . . . . page 1-7
COMPONENT
CHECKLIST
A typical Rosemount Analytical OPM 3000 Opacity/Dust Density Monitor
should contain the items shown in Figure 1-1. Sheet 1 shows the assembly on
the transceiver side, and sheet 2 shows the assembly on the retro reflector
side. Items on the mounting panel are factory installed and come as shown.
Figure 1-2 shows the transceiver assembly with the optional stainless steel
weather cover.
Due to the availability of optional accessories, the system package will vary.
Use the product matrix, in Table , to compare your order number against your
unit. The first part of the matrix defines the model. The last part defines the
various options and features of the OPM 3000. Ensure the features and
options specified by your order number are on or included with the unit.
SYSTEM OVERVIEW
General The OPM 3000 Opacity/Dust Density Monitor provides continuous, low
maintenance, precision measurement of opacity and optical density in
industrial applications. It is a cost-effective instrument that serves as an aid in
operating pollution and/or process control equipment.
Opacity refers to the amount of light being scattered or absorbed by particles
in the light beam path. An opacity or dust density transmitter (also called a
transmissometer) measures the particulate level of stack emissions. One of
the most common reasons for measuring opacity is to comply with
Environmental Protection Agency (EPA) or other national requirements.
Federal regulations for new emission sources and many state regulations for
both new and existing sources specify maximum limits for stack emission
opacity.
A transmissometer can be used in a variety of applications. Those
applications include monitoring the efficiency of emission control systems,
detecting broken bags in baghouses, and determining the time rapping cycles
for electrostatic precipitators. Another application is to gauge the
effectiveness of injecting flue gas conditioning agents used to improve
electrostatic precipitator performance.

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
1-2
Figure 1-1. Typical System Package (Sheet 1 of 2)
38440032
OPM 3000
ESC
Model:
Serial:
Analytical
OPM 3000
Opacity/Dust Density
Monitor
Instruction Manual
IM-105-3000Rev.1.0
May2006
12345
67890
1
2
3
4
5
6
7
8
9
10
1. Control Unit
2. Zero Jig
3. Mounting Plate
4. Instruction Manual
5. Air Blower
6. Air Filter
7. Air Hose with Clamps
8. Duplexer
9. Transceiver with
Air Plenum attached
Note: The optional weather
covers are not shown
in the typical system
package.
10. Terminal Board

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
1-3
OPM 3000
Figure 1-1. Typical System
Package (Sheet 2 of 2)
Opacity data can also serve as a rough indicator of combustion efficiency.
Extreme changes in opacity may indicate inefficient combustion or boiler
problems. Because the transmitter gives accurate, immediate response data,
corrective actions can be taken as soon as problems occur. This data serves
not only the compliance requirement of pollution regulation standards but also
as a means to achieve improved efficiency and operating profit.
Originally, a trained smoke reader determined the particulate level of stack
emissions solely by observation. The opacity of the plume was judged in
reference to a standard Ringelmann scale of 0 to 5. These determinations
tended to be influenced by several sources of error such as sky haze, sun
position, and the subjective determination of the observer. These sources of
error, especially at lower opacity levels, can produce highly variable readings
even when performed by a trained observer.
OPM 3000 System
Features
Transmissometer/Retro Reflector
The OPM 3000 is a precision, double-pass, dual beam Transmissometer that
consists of a transceiver (transmitter/receiver) mounted on one side of a stack
or duct and a passive reflector mounted on the opposite side. The light
source, photo detectors and all measurement/reference optics used in opacity
measurement are housed in the transceiver.
The function of the reflector is to return the measurement beam to the
detector in the transceiver, creating a double pass across the process stream.
The standard reflector is used for measurement path lengths up to 15 feet
(4,6 m). For longer path lengths, maximum 60 feet (18,3 m), reflectors, optical
parts and electronics will vary.
38440041
Model:
Serial:
1
2
Notes: 1. Install air hose from the blower tee on
the transceiver assembly.
2. The optional weather covers are not
shown in the typical system package.
1. Mounting Plate
2. Retro Reflector with
Air Plenum attached

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
1-4
Figure 1-2. Transceiver
Assembly with Weather Cover
Control Unit
Mounted in a control room environment, the OPM 3000 control unit provides
instrument control functions (Section 4: Normal Operation for details).
Optional Air Purge Weather Cover System
The transceiver and reflector may be mounted in weather covers. The
weather covers are fairly compact to allow movement around them even on a
three-foot walkway or platform. They protect the stack-mounted components
from dirt, moisture, stack temperatures within the specified ambient
temperatures limits, and errant air currents around the stack.
The air purge system constantly circulates air past the optical window. The
airflow is directed through the hose to an air plenum on the stack side of the
optical window. The airflow in the air plenum area results in reduced pressure
and increased velocity. This venturi effect tends to continually draw the air
around the optical window into the purge air stream, thereby keeping the lens
clean for long periods.
Alignment System
The OPM 3000 includes a built-in through-the-lens alignment system. The
alignment target can be viewed through a window on the transceiver.
Adjustments to changes in alignment are provided by a 3-point alignment
system, which is integral to the air plenum.
Cabling
The standard cabling used between the stack-mounted units and the control
unit is at minimum a 2-pair, #22 AWG, twisted, shielded cable. More pairs or
larger than 20 AWG is acceptable.
38440039
Transceiver
Filter
Air Blower
Mounting
Plate
Duplexer
Weather
Cover
Control Unit

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
1-5
OPM 3000
Normal Mode of
Operation
The dual beam measurement system has a stack mounted transmissometer
sensor system that consists of an optical transceiver mounted on one side of
the stack and a retro reflector mounted on the other (Figure 1-3). To avoid
errors due to ambient light, the lamp is electronically modulated and projects
a collimated beam of light, which is split into a reference beam, and a
measurement beam by an optical beam splitter. The reference beam is
directed to the reference detector (RD). The measurement beam is projected
across the stack to a retro reflector that returns the beam back across the
stack to a beam splitter and directs the measurement beam to the
measurement detector (MD). A portion of the returning light is also sent to the
TTL (Thru The Lens) bulls-eye target viewed through a window provided at
the rear of the transmissometer. The bulls-eye is used to correct changes in
alignment and is unique in that no moving parts are used.
The ratio of the measurement and reference detectors is used to provide a
transmittance-squared (T2) signal. Because the same light source is used for
both detectors, and a measurement / reference ratio is used throughout for
the calculations, the monitor is insensitive to variations in light intensity. Since
all measurements are made on a ratio basis, all resulting computations are
independent of the absolute intensity of the light source or contamination of
the optics associated with the collection and focusing of the energy from the
lamp. The T2signal is converted to a current format and sent to the control
unit for processing. At the control unit the signal is processed to read 0-100%
opacity, and provide alarms and outputs.
Figure 1-3. Component
Relationships
RD MD
Aperture P
Main Lamp
TTL Bulls-Eye
Projection Lens Retro Reflector
Aperture V
38440001

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
1-6
SPECIFICATIONS Specifications for the OPM 3000 system are listed in Table 1-1.
Table 1-1. OPM 3000
Specifications OPM 3000 Specifications
Control Unit
Enclosure Panel mounted IP65/NEMA 4X Dimensions 3.8 in. x 3.8
in. x 2.5 in. (96 x 96 x 64 mm). Power 20.4 to 28.8VDC
< 10% ripple, 400 mA.
Digital Display LED backlight
Ambient Temperature Range +32 to +122oF (0 to +50oC)
Power Requirements 24 VDC
Alarm Time Delay and Set Point Field programmable, 10 pnp (source) outputs 24 VDC;
optional relays available.
Alarm Reset Manual or Automatic
Analog Outputs Two 12-bit Analog outputs: 4-20 mA, 0-10 VDC
OPLR/Exit Correlation
(Lx / 2Lt)
0.2 to 3.0
Calibration Check Options Manual zero and span calibrate with dedicated zero
reflector or Zero with clear stack condition.
RS485 Two Ports each Modbus or RS485 networking
I/O Expansion Port Up to 128 additional I/O
Battery Back 7 years typical
Transceiver/Reflector
Enclosure NEMA 4 watertight enclosure. Power 120/240 VAC,
50/60 Hz
Path Length 3 feet to 53 feet (0.9 to 15.9 meters)
Optical System Double Pass
Reflector Type 1 (plastic) reflector assembly
Light Source Aging
Compensation
Automatic
Light Source Life 45,000 hours (>5 years)
Ambient Temperature Limits -40 to + 130oF (-40 to +54oC)
Process Gas Up to 750oF (400oC)
Alignment Verification Built-in through-the-lens system standard
Mounting Flanges 3 inch IPS, 150 lb flange, standard
Ambient Light Immunity Solid-state electronic light modulation
Wiring 2 pair twisted shielded cable, 22 AWG
Design and Performance
Peak and Mean Spectral
Response
Photopic; 515 to 585 nm less than 10% of peak
response outside the desired 400 to 700 nm region.
Angle of View <4.0ofrom optical axis
Angle of Projection <4.0ofrom optical axis
Calibration Error <±2% of full scale
Response time <10 second
Zero Drift <1% (24 hours)
Calibration Drift <1% (24 hours)
Operational Period 6 Months

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
1-7
OPM 3000
OPM 3000 - ORDERING
INFORMATION
Select complete model number from the Product Matrix, Table 1-2.
Table 1-2. Product Matrix
OPM3000 Opacity/Dust Density Monitor Non-compliant
Code Intelligent Electronics
01 Basic Unit – Digital Display, (2) 4-20 mA Outputs, (4) Alarm PNP’s, RS 232/485, Modbus
Code Transceiver and Path Length
11 3-15’ Path Length
12 >15-21’ Path Length
13 >21-40’ Path Length
14 >40-53’ Path Length
Code Weather Cover and Blowers
00 None
01 Weather Covers and Single Blower/Tee
02 Weather Covers Only
03 Weather Covers and Dual Blowers
Code Zero Jig Type
00 None
01 Zero Jig and a 84% Neutral Density Filter
Code Dust Density Calculation
01 None
02 With Dust Density Calculation (mg/m3)
OPM30000112020001 Example

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
1-8

Instruction Manual
IM-105-3000, Rev 2.0
November 2008 OPM 3000
http://www.raihome.com
Section 2 Installation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . page 2-2
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-5
Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 2-13
NOTE
If installed path length is not within 10% of the factory set path length, return
the unit to the factory so the path length can be reset.
OVERVIEW This section describes:
• Considerations prior to installation.
• Mechanical installation procedures, including the applicable drawings
and pictures to assist in the process.
• Wiring requirements for the OPM 3000 system.
• The beam alignment procedure.
• Output connections for alarms and recording devices.
Before installing this equipment, read the “Safety instructions for the wiring and installation
of this apparatus” in Appendix B. Failure to follow safety instructions could result in serious
injury or death.
Install all protective equipment covers and safety ground leads after installation. Failure to
install covers and ground leads could result in serious injury or death.
Before making any electrical connections, make sure the AC power source is switched off.
Failure to do so could cause personal injury or even death. Make sure that the voltage and
frequency of the power source match the designations on the analyzer component tags.

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
2-2
INSTALLATION
CONSIDERATIONS
Choose an Installation
Site
The primary considerations for choosing a site for the OPM 3000 are
accessibility, ambient environmental conditions, and obtaining a
representative sample of the process. The following general guidelines should
be considered.
Accessibility Locate the instrument where it will provide safe access for periodic
maintenance and inspection. A platform or walkway is required for access to
the sensors and weather covers. The optimum condition is to have the
mounting flanges and weather covers approximately 5 feet (1,5 m) above the
floor. A minimum of 12 in. (305 mm) from the bottom of the weather cover to
the floor is required in order to remove the air filters.
Clearance Installation clearances for the transceiver, retro reflector and optional weather
covers are shown in Figure 2-1.
Environment Locate the stack-mounted units in an area with ambient temperatures
between -40oto +130oF (-40oto 54oC). (Consult the factory for other
temperature ranges.) Areas that are clean and dry are desirable. Avoid areas
with condensation.
Maintenance intervals are directly related to the installation environment.
Intervals can vary from 2 to 3 months in fairly clean environments, to twice a
month in dirty environments. Lens cleaning is a function of the ambient
conditions and cleanliness of the purge air.
Choose a location that will minimize excessive vibration or shock.
Locate the control unit in an easily accessible area with temperatures
between +32oto 122oF (0oto 50oC). To permit the operator to read and/or
change controls, the unit should not be mounted higher than five feet from
floor level.
Sample Area To achieve a representative sample, the accepted practice is to have the
measurement path of the instrument directly in the center of the stack. An
area should be chosen where the gases are not stratified in the stack or duct.
When installed near a bend, install the transceiver in the plane defined by the
bend; refer to "Regulatory/Process Considerations". Avoid locations where
large amounts of condensed water is present.
Stack Exit The transceiver should be located a minimum of two stack diameters from the
stack exit. Ideally the transceiver should be installed eight to ten stack
diameters from the stack exit.

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
2-3
OPM 3000
Figure 2-1. Installation Clearances
and Weather Cover Dimensions

Instruction Manual
IM-105-3000, Rev 2.0
November 2008
OPM 3000
2-4
Regulatory/Process
Considerations
The EPA has established the following guidelines for choosing an opacity/dust
density monitor installation site:
1. Locate the transmitter across a section of a duct or stack that will
provide a particulate matter flow through the path of the transmitter
beam representative of the duct or stack flow.
2. Ensure the transmitter location is down-stream from all particulate
control equipment.
3. Locate the transmitter as far from bends and obstructions as practical.
4. If a transmitter is to be located less than 4 duct diameters downstream
from a bend, install the transmitter in the plane defined by the bend, as
shown in Figure 2-2.
5. Ideally, locate the transmitter eight to ten stack diameters upstream from
the stack exit and three to five diameters downstream from any bends,
junctions, or other constrictions in the stack or duct.
For best results, mount the transceiver and retro reflector modules so
the light beam is exactly perpendicular to the stack or duct and the
beam goes through the center. Do not install the transmitter
downstream of a wet scrubber. The water droplets introduced to the gas
stream by such equipment will interfere with the opacity readings. For
an accurate measurement under these conditions, choose a location
upstream from a wet scrubber or a location downstream from the
scrubber where the water droplets are vaporized by the reheating of the
gas.
Figure 2-2. Transmitter Location
Less than
4 duct
diameters
38440028
Note: The transceiver and retro reflector are shown
with the optional weather covers installed.