OSI OFS 2000CW User manual

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
User's Guide
OFS 2000CW
Optical Flow Sensor
03/28/13
OPTICAL SCIENTIFIC INC
Tel: [phone]
Fax: [phone]
2 Metropolitan Ct, Suite 6
Gaithersburg, MD 20878 USA
www.opticalscientific.com

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
i
Revision Log
Rev Date
Description of Changes
11/29/2011
Production Release
04/11/2012
Added explanation for second current loop full scale
03/28/2013
Updated OFS 2000C User’s Guide to create -CW model User’s Guide
OFS-2000 Certifications
UL 3101-1:1993
CSA C22.2 No. 1010.1:92
IEC 61010:1999
OSi is an ISO-9001 Registered Company

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
ii
Table of Contents
1 OFS -2000CW OVERVIEW ......................................................................................................................... 1
1.1 Theory of Operation .............................................................................................................................. 1
1.2 OFS -2000CW Specifications................................................................................................................ 3
1.3 Description of Units............................................................................................................................... 4
1.3.1 OFS 2000CW Transmitter............................................................................................................... 5
1.4 OFS 2000CW Receiver (RX) Unit.......................................................................................................... 6
1.5 Control Box........................................................................................................................................... 7
1.6 Temperature Probe..............................................................................................................................10
1.7 Activator Heater ...................................................................................................................................10
2 Pre –Installation.........................................................................................................................................11
2.1 OFS Placement....................................................................................................................................11
2.2 OFS 2000CW Sensor Placement.........................................................................................................12
2.3 Flange Alignment Guidelines................................................................................................................13
2.4 Flange Mounting Examples..................................................................................................................14
2.5 Flange Pipe Extension..........................................................................................................................15
2.6 Flange Pipe Mounting ..........................................................................................................................16
3 Installation..................................................................................................................................................17
3.1 Required at Transmitter or Receiver Location.......................................................................................17
3.2 Required at Control Unit Location.........................................................................................................17
3.3 Mechanical...........................................................................................................................................18
3.3.1 TX/RX Units...................................................................................................................................18
3.3.2 Control Units..................................................................................................................................20
3.4 Purge Air..............................................................................................................................................21
3.5 OFS in Hazardous or High Temperature Applications...........................................................................23
3.6 Pressurization Air (Z-Purge Air)............................................................................................................24
3.6.1 Unit Tubing Instructions .................................................................................................................26
3.6.2 Pressurization Unit Set Up.............................................................................................................26
3.6.3 Pressurization Unit Operation.........................................................................................................27
3.7 AC Power Connections........................................................................................................................28
3.7.1 Transmitter Unit.............................................................................................................................28
3.7.2 Control Box....................................................................................................................................28
3.8 User Interface Connections..................................................................................................................29
3.9 OFS 200CW Interconnecting Cables....................................................................................................30
3.10 AGC Cable Connections for OFS 2000CW Models.............................................................................31
3.11 OFS Receiver Cable ..........................................................................................................................31
3.11.1 Temperature Probe Interconnect..................................................................................................32
3.11.2 Activator Heater Interconnect.......................................................................................................32
3.12 4-20 mA Current Loop Connections....................................................................................................33
3.13 TB2 Fault / Cal Relays & External Calibration.....................................................................................34
3.13.1 Fault Relay ..................................................................................................................................34
3.13.2 Cal Relay.....................................................................................................................................34
3.13.3 External Calibration Input.............................................................................................................34
3.14 Computer Connection.........................................................................................................................35
3.14.1 HyperTerminal Setup...................................................................................................................36
4 OFS System Configuration Setup ...............................................................................................................37
4.1 Checking Communications...................................................................................................................37
4.2 OFS 2000C Setup................................................................................................................................37
4.2.1 Units of Measurement....................................................................................................................37
4.2.2 Time Constant ...............................................................................................................................38
4.2.3 Serial Output..................................................................................................................................38
4.2.4 Current Loop..................................................................................................................................38
4.2.5 Correction Factor...........................................................................................................................39
4.2.6 Multiple Point Correction Factor.....................................................................................................40
4.2.7 Duct Area Data..............................................................................................................................41
4.2.8 Calibration Percentage (Optional) ..................................................................................................41
5 Poll Commands & Data Output...................................................................................................................42
5.1 "A" Poll (Short Data String) Output .......................................................................................................42

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
iii
5.1.1 "A" Poll Response Bytes................................................................................................................42
5.2 "C" Poll (Long Data String) Format.......................................................................................................43
5.2.1 “C” Poll Response Bytes ................................................................................................................43
5.2.2 Description of Status Indicator Codes (Bytes 29-32).......................................................................44
6 Transmitter and Receiver Setup..................................................................................................................45
6.1 Transmitter Setup.................................................................................................................................45
6.2 Receiver Setup.....................................................................................................................................46
7 Optical Alignment .......................................................................................................................................47
7.1.1 Avoiding Receiver Saturation.........................................................................................................50
8 Correlation..................................................................................................................................................51
9 Initial Check and Start-Up...........................................................................................................................52
9.1 Initial Check.........................................................................................................................................52
9.2 Visual Indicators...................................................................................................................................52
10 Maintenance.............................................................................................................................................54
10.1 Safety ................................................................................................................................................54
10.2 Preventive Maintenance.....................................................................................................................54
10.2.1 Window Cleaning Procedure........................................................................................................55
11 Troubleshooting........................................................................................................................................56
11.1 General Troubleshooting Guidelines...................................................................................................56
11.2 Control Enclosure Troubleshooting.....................................................................................................57
11.2.1 DSP lndicator LEDs.....................................................................................................................57
11.2.2 Control/Interface Indicators..........................................................................................................57
11.3 Transmitter Troubleshooting...............................................................................................................57
11.3.1 Transmitter "Power" Led Not Lit ...................................................................................................57
11.3.2 Transmitter "Signal" Led Not Lit....................................................................................................57
11.4 Receiver Troubleshooting...................................................................................................................57
11.4.1 Receiver "Power" Led Not Lit.......................................................................................................57
11.4.2 Receiver "Signal" Led Not Lit .......................................................................................................58
11.5 Error Messages..................................................................................................................................59
11.5.1 Fault (1) A and/or B Out of Range................................................................................................59
11.5.2 Warning (2) Velocity Out Of Range ..............................................................................................59
11.5.3 Fault (3) Input Voltage Out of Range............................................................................................59
11.5.4 Fault (5) Heating Activity Error......................................................................................................59
11.5.5 Fault (6) Temperature Probe Error ...............................................................................................59
11.5.6 Fault (7) Pressure Probe Error .....................................................................................................59
11.5.7 Warning (9) Clean Lens ...............................................................................................................59
12 Spare Parts ..............................................................................................................................................60
12.1 Recommended Spare Parts ...............................................................................................................60
12.2 Available Spare Parts.........................................................................................................................60
13 Technical Support.....................................................................................................................................61

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
iv
Table of Figures
Figure 1.1 OFS 2000CW Basic Components.................................................................................................. 1
Figure 1.2 OFS 2000CW System Components............................................................................................... 4
Figure 1.3 OFS 2000CW Transmitter.............................................................................................................. 5
Figure 1.4 OFS 2000CW Receiver.................................................................................................................. 6
Figure 1.5 OFS 2000CW Control Box............................................................................................................. 7
Figure 1.6 OFS Control Box............................................................................................................................ 8
Figure 1.7 Control Display .............................................................................................................................. 8
Figure 1.8 Pressure Sensor............................................................................................................................ 9
Figure 1.9 Temperature Probe.......................................................................................................................10
Figure 1.10 Activator Heater..........................................................................................................................10
Figure 1.11 Heater Current Sensor................................................................................................................10
Figure 2.1 OFS Placement ............................................................................................................................11
Figure 2.2 Typical Sensor Placement.............................................................................................................12
Figure 2.3 Flange Installation (cutaway).........................................................................................................13
Figure 2.4 Measured Flow Cross Section.......................................................................................................15
Figure 2.5 Flange Installation - Incorrect........................................................................................................16
Figure 2.6 Flange Installation - Correct..........................................................................................................16
Figure 2.7 Common Flange Dimensions........................................................................................................16
Figure 3.1 Common Vertical Installation.........................................................................................................18
Figure 3.2 Common Horizontal Installation.....................................................................................................18
Figure 3.3 OFS Mounting Hardware...............................................................................................................18
Figure 3.4 OFS TX/RX Overall Dimensions....................................................................................................19
Figure 3.5 Control Box Mounting Dimensions ................................................................................................20
Figure 3.6 Purge Air Detail.............................................................................................................................21
Figure 3.7 Rotameter (flow meter) .................................................................................................................21
Figure 3.8 "Natural" Air Purge........................................................................................................................21
Figure 3.9 Compressed Air Purge..................................................................................................................21
Figure 3.10 Purge Air at 90° to Vertical Flow..................................................................................................22
Figure 3.11 Rotameter Installation.................................................................................................................22
Figure 3.12 Typical Gate Valve Installation....................................................................................................23
Figure 3.13 Z-Purge Control Unit...................................................................................................................24
Figure 3.14 Control Unit Mounting Dimensions ..............................................................................................24
Figure 3.15 Typical Z-Purge Control Unit.......................................................................................................25
Figure 3.16 TX/RX Z-Purge Arrangement......................................................................................................25
Figure 3.17 Control Box Z-Purge Arrangement ..............................................................................................26
Figure 3.18 Transmitter AC Connections .......................................................................................................28
Figure 3.19 Control Box AC Connections.......................................................................................................28
Figure 3.20 User Analog Interface Connections.............................................................................................29
Figure 3.21 J5 Serial Port..............................................................................................................................29
Figure 3.22 OFS2000CW Interconnects........................................................................................................30
Figure 3.23 Receiver Cable Connections.......................................................................................................30
Figure 3.24 TX AGC Cable Connection..........................................................................................................31
Figure 3.25 RX AGC Cable Connection.........................................................................................................31
Figure 3.26 TB3 Connections........................................................................................................................33
Figure 3.27 Terminal Block 2.........................................................................................................................34
Figure 3.28 OFS 200CW Computer Connection.............................................................................................35
Figure 4.1 HyperTerminal Open.....................................................................................................................37
Figure 4.2 "V" Poll Output..............................................................................................................................37
Figure 4.3 Units of Measure...........................................................................................................................37
Figure 4.4 Setup: Time Constant ...................................................................................................................38
Figure 4.5 Serial Output.................................................................................................................................38
Figure 4.6 Current Loop 1..............................................................................................................................38
Figure 4.7 Current Loop Assignments............................................................................................................39
Figure 4.8 Correction Factor Entry.................................................................................................................39
Figure 4.9 Curve Fitting Setup.......................................................................................................................40
Figure 4.10 Curve Fitting Point Entry .............................................................................................................40

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
v
Figure 4.11 Curve Fitting Entry Check ...........................................................................................................40
Figure 4.12 Clearing Set Points.....................................................................................................................41
Figure 4.13 Duct Area....................................................................................................................................41
Figure 4.14 Calibration Percentage N/A.........................................................................................................41
Figure 6.1 OFS 2000CW TX Module..............................................................................................................45
Figure 6.2 OFS 2000CW RX Window............................................................................................................45
Figure 6.3 Centering Light Beam ...................................................................................................................45
Figure 6.4 TX Rear View................................................................................................................................45
Figure 6.5 Receiver "A" & "B" Lenses ............................................................................................................46
Figure 6.6 Receiver LEDs and Flow Direction................................................................................................46
Figure 7.1 Receiver Window "Cat’s Eyes" ......................................................................................................47
Figure 7.2 Transmitter Module.......................................................................................................................48
Figure 7.3 Beam Centering............................................................................................................................48
Figure 7.4 Front Panel Display (example).....................................................................................................48
Figure 7.5 Filter Material Insertion..................................................................................................................50
Figure 9.1 Transmitter LEDs..........................................................................................................................52
Figure 9.2 Receiver LEDs..............................................................................................................................52
Figure 9.3 Control Enclosure Display.............................................................................................................53
Figure 9.4 Control & DSP Indicator LED's......................................................................................................53
Figure 10.1 Window Cleaning........................................................................................................................55
Figure 11.1 DSP Indicators............................................................................................................................57
Figure 11.2 Control/Interface LEDs................................................................................................................57

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
vi
Caveats
Only trained personnel are allowed to service this equipment.
The OFS shall only be used in a manner specified by the manufacturer.
This equipment contains hazardous voltages.
Disconnect AC power before servicing.
Optical Scientific, Inc. will not be held liable for any accident, injury to
personnel, or damage to property incurred while operating or servicing this
equipment. Implementation and enforcement of proper work safety procedures
is solely the responsibility of the user, user employees or contracted personnel.
!CAUTION!
Read the entire User's Guide before proceeding with any
installation or maintenance activity.

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
1
1 OFS -2000CW OVERVIEW
1.1 Theory of Operation
Scintillation is the variation of light caused by it’s passage through pockets of air with different temperature and
density. It’s what makes the stars seem to twinkle in the night sky. OFS uses scintillation in air flow to
determine velocity. Our proven measurement technology, originally developed and patented for use in
atmospheric visibility and turbulence detecting instruments, offers unequalled response and accuracy in air
flow sensing.
This measurement is not affected by temperature and pressure.
It is completely non-intrusive to the air flow.
The basic system consists of:
Transmitter a stand-alone unit that emits an eye-safe red light beam
Receiver unit containing 2 photodetectors and signal amplifiers
Control unit that houses the DC power supply, DSP, control and user interface
Transmitter
Receiver
Control Unit
Figure 1.1 OFS 2000CW Basic Components
The LED in the transmitter emits a light beam which illuminates twin photodetectors in the receiver.
The received signal is amplified and sent to the Digital Signal Processor (DSP) in the Control Unit. The results
are shown on the front panel display and relayed to the customer either through a 4-20 mA current loop or
through an RS-232 interface.
The system is designed to fit standard commercial/industrial installations and to easily interface with PC, PLC,
DAS, CEM - almost any data collection device
The OFS -2000CW is a valuable tool for:
Environmental Monitoring (factory and power plant stacks, refinery flare stacks)
Process control. (gas transfer, boiler and incinerator efficiency)
Local airflow monitoring (exhaust vents, wind tunnels)
Environmental Monitoring
Process Control
Local Airflow Monitoring
Emissions-regulated industries
can use this information to
calculate volumetric flow from
their smokestacks. OFS is EPA -
compliant.
The OFS can measure the speed
of the air or gas flow in an
industrial process. The data can
be integrated into the monitoring
and control system.
OFS has been used to measure
airflow in underground tunnel
vents, roof exhaust vents, wind
tunnels and other applications

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
2

Optical Scientific Inc
OFS 2000CW User’s Guide
P/N 1910-905
Rev. 03/28/13
3
1.2 OFS -2000CW Specifications
Flow Performance
Technique
Optical scintillation
Velocity Range
1.0 to 40 m/s velocity
Path Distance
2 to 10+ meters (6 to 30+ feet)
Accuracy
2% of reading
Resolution
0.1 m/s
Averaging Time
User selectable: 3 sec to 600 sec
Long Term Drift
<1% >6 months
Media Temperature
No upper limit (for cold air applications an ‘activator’ may be required)
Light Source
670 nm red LED
Beam Divergence
5 degrees
Optics
Quartz
Purge
Purge fittings supplied
(Nominal recommendation is
4 CFM per system)
Factory-supplied instrument –grade purged air with
1-2 CFM
Maintenance
Diagnostics
Continuous monitoring of sensor status including power supply voltage
check, performance check, optics contamination, etc
Indicators
TX Optical Unit - LEDs indicating power ON & correct operation
RX Optical Unit - LEDs indicating power ON & correct operation
Control Box - LEDs indicating correct operation
Operational Environment
Ambient Temperature
-40 to 60 C
Dust Intrusion
IP65
Moisture
0-100% condensing with dry purge air supplied
Data Output
Four 4-20 mA optical isolated outputs
Loop 1 –Velocity
Loop 3 –Temperature (optional)
Loop 2 - Volume
Loop 4 –Pressure (optional)
Two relays for fault and calibration check indications
Control/Data Interface
RS-232 ASCII, DB9 exterior serial port. USB adapter included
Baud rate (9600 standard) 8 data bits, no parity, 1 stop bit
2 Data output string formats
Short with only velocity and P/F status
Long with all velocity and status data
Front panel backlit LED display
Power Requirements
Fuse, Surge, & EMI protected
Transmitter Unit
Universal 100-240 VAC, 50/60 Hz, 12 VA
Control Box
Universal 100-240 VAC, 50/60 Hz, 40 VA
Activator Heater
120 VAC, 50/60 Hz, 15A
Physical Characteristics
Weight
TX & RX Optical Units
5 kg ea
Control Box (NEMA-4),
4.7 kg
Flange Adapter (spool piece) (2)
3 kg ea
Dimensions
TX & RX Optical Units
15 x 15 x 14 cm ea
Control Box (NEMA-4),
34 x 28 x 17 cm
Flanged Adapter (spool piece)
9-in. dia. (150# 4” ANSI bolt pattern on user
end)
6-inch (15 cm) long
Materials
TX & RX Optical Units
Aluminum with powder-coat paint
Control Box
Aluminum with powder-coat paint (NEMA-4)
Adapter
Aluminum with powder-coat paint