OSI OFS-2000FW User manual

Optical Scientific Inc
OFS 2000FW User’s Guide
P/N 1910-901-1
User's Guide
OFS -2000FW
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 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
i
Revision Log
Rev Date
Description of Changes
3/23/2004
Production Release
3/24/2005
Change on pages 3, 14 and 27
6/8/05
Change the interface board from single current loop to dual current loops.
10/9/06
Release Model 2000W with Automatic Transmitter Power Feedback Control
5/11/07
Add Installation Procedure Summary in Appendix B.
7/1/07
Change new address
08/04/10
Update OFS 2000W Wiring Diagram in Appendix A p39
03/28/2013
Re-written & re-organized to include –FW model, Thermal Activator, enhanced Purge
and Z-Purge sections, updated procedures and specifications.
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 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
ii
Table of Contents
1 OFS -2000FW OVERVIEW.......................................................................................................................... 1
1.1 Theory of Operation .............................................................................................................................. 1
1.2 OFS -2000FW Specifications ................................................................................................................ 2
1.3 Description of Units............................................................................................................................... 3
1.4 Transmitter (TX) Unit............................................................................................................................. 4
1.5 OFS 2000FW Receiver (RX) Unit.......................................................................................................... 5
1.6 Control Box(es) Indoor And Outdoor...................................................................................................... 6
1.6.1 Outdoor Control Box ....................................................................................................................... 6
1.6.2 Indoor Control Box.......................................................................................................................... 7
2 Pre –Installation.......................................................................................................................................... 8
2.1 OFS Placement..................................................................................................................................... 8
2.2 Flange Alignment Guidelines................................................................................................................. 9
2.3 Flange Mounting Examples..................................................................................................................10
2.4 Flange Pipe Extension..........................................................................................................................11
2.5 Flange Pipe Mounting ..........................................................................................................................12
3 Installation..................................................................................................................................................13
3.1 Required at Transmitter or Receiver Location.......................................................................................13
3.2 Required at Control Unit Location.........................................................................................................13
3.3 Mechanical...........................................................................................................................................14
3.3.1 TX/RX Units...................................................................................................................................14
3.3.2 Control Units..................................................................................................................................16
3.4 Purge Air..............................................................................................................................................17
3.5 OFS in Hazardous or High Temperature Applications...........................................................................19
3.6 Pressurization Air (Z-Purge Air)............................................................................................................20
3.6.1 Unit Tubing Instructions .................................................................................................................22
3.6.2 Pressurization Unit Set Up.............................................................................................................22
3.6.3 Pressurization Unit Operation.........................................................................................................23
3.7 AC Power Connections........................................................................................................................24
3.7.1 Transmitter Unit.............................................................................................................................24
3.7.2 Control Boxes................................................................................................................................24
3.8 User Interface Connections..................................................................................................................25
3.9 OFS 2000FW Interconnecting Cables...................................................................................................26
3.10 AGC Cable Connections for OFS 2000FW Models.............................................................................27
3.11 OFS Receiver Cable ..........................................................................................................................27
3.12 4-20 mA Current Loop And Relay Connections...................................................................................28
3.13 RS-232 Connections..........................................................................................................................29
3.13.1 Limited Distance Modem (LDM) Connections...............................................................................29
3.13.2 Fiber Optic Modem (FOM) Connections.......................................................................................30
3.14 Computer Connection.........................................................................................................................31
4 Poll Commands & Data Output...................................................................................................................32
4.1 "A" Poll (Short Data String) Output .......................................................................................................32
4.1.1 "A" Poll Response Bytes................................................................................................................32
4.2 "C" Poll (Long Data String) Format.......................................................................................................32
4.2.1 “C” Poll Response Bytes ................................................................................................................33
4.2.2 Description of Status Indicator Codes (Bytes 29-32).......................................................................34
4.3 Reading The Output Data.....................................................................................................................35
5 Data Collection...........................................................................................................................................36
5.1 Using “C” Poll.......................................................................................................................................37
5.2 Using Continuous Polling .....................................................................................................................37
6 Optical Alignment .......................................................................................................................................38
6.1 Receiver Setup.....................................................................................................................................38
6.2 Transmitter Setup.................................................................................................................................39
6.2.1 Transmitter Aiming Considerations.................................................................................................40
6.2.2 Avoiding Receiver Saturation.........................................................................................................42
7 Correlation..................................................................................................................................................43
8 Initial Check and Start-Up...........................................................................................................................44
8.1 Initial Check.........................................................................................................................................44

Optical Scientific Inc
OFS 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
iii
8.1.1 Visual Indicators ............................................................................................................................44
8.2 OFS Start-Up.......................................................................................................................................45
8.2.1 OFS Initial Display Sequence.........................................................................................................46
8.2.2 Display and Keypad.......................................................................................................................47
8.2.3 Check Firmware Version Procedure...............................................................................................49
8.2.4 Correction Factor...........................................................................................................................50
8.2.5 Curve Fitting..................................................................................................................................50
8.2.6 Calibration Verification...................................................................................................................51
8.3 External Calibration (RATA) .................................................................................................................52
9 Maintenance...............................................................................................................................................53
9.1 Safety ..................................................................................................................................................53
9.2 Preventive Maintenance.......................................................................................................................53
9.2.1 Window Cleaning Procedure..........................................................................................................54
10 Troubleshooting........................................................................................................................................55
10.1 General Troubleshooting Guidelines...................................................................................................56
10.2 Power and Signal Checks...................................................................................................................57
10.2.1 DSP Power and Signal.................................................................................................................57
10.2.2 Transmitter "Power" Led Not Lit ...................................................................................................57
10.2.3 Transmitter "Signal" Led Not Lit....................................................................................................57
10.2.4 Receiver "Power" Led Not Lit .......................................................................................................57
10.2.5 Receiver "Signal" Led Not Lit .......................................................................................................57
10.2.6 Signal Voltage Checks - Receiver................................................................................................58
10.2.7 Signal Voltage Checks –Receiver/Control Unit............................................................................58
10.3 Control Box Troubleshooting ..............................................................................................................59
10.4 Error Messages..................................................................................................................................59
10.4.1 Channel A/B Out of Range...........................................................................................................59
10.4.2 DSP Timeout ...............................................................................................................................59
11 Spare Parts ..............................................................................................................................................60
11.1 Recommended Spare Parts ...............................................................................................................60
11.2 Available Spare Parts.........................................................................................................................60
12 Appendix A OFS 2000 Thermal Activator..................................................................................................61
12.1 OVERVIEW........................................................................................................................................61
12.1.1 Theory of Operation.....................................................................................................................61
12.2 General Heater Specifications............................................................................................................62
12.3 Thermal Activator Wiring ....................................................................................................................63
12.4 Description of Units............................................................................................................................64
12.5 Thermal Activator...............................................................................................................................65
13 Pre –Installation.......................................................................................................................................66
13.1 Thermal Activator Placement..............................................................................................................66
14 Installation................................................................................................................................................67
15 Appendix B OFS Curve Fitting Procedure.................................................................................................68
15.1 Introduction........................................................................................................................................68
15.2 Equipment Setup................................................................................................................................69
15.2.1 OFS and Computer Setup............................................................................................................69
15.2.2 Curve Fitting Procedure ...............................................................................................................69
15.3 Curve Fitting Data Entry.....................................................................................................................70
15.4 Curve Fitting Verification.....................................................................................................................71
16 Technical Support.....................................................................................................................................72
16.1 Before Calling Technical Support:.......................................................................................................72

Optical Scientific Inc
OFS 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
iv
Table of Figures
Figure 1.1 OFS Basic Components................................................................................................................. 1
Figure 1.2 OFS 2000FW System Components................................................................................................ 3
Figure 1.3 OFS 2000FW Transmitter.............................................................................................................. 4
Figure 1.4 OFS 2000FW Receiver.................................................................................................................. 5
Figure 1.5 OFS Control Box (Outdoor)............................................................................................................ 6
Figure 1.6 Control Box Interior........................................................................................................................ 7
Figure 1.7 Control Box Front Panel................................................................................................................. 7
Figure 1.8 Control Box Rear Panel ................................................................................................................. 7
Figure 1.9 Interface Board.............................................................................................................................. 7
Figure 2.1 OFS Placement ............................................................................................................................. 8
Figure 2.2 Flange Installation (cutaway).......................................................................................................... 9
Figure 2.3 Measured Flow Cross Section.......................................................................................................11
Figure 2.4 Flange Installation - Incorrect........................................................................................................12
Figure 2.5 Flange Installation - Correct..........................................................................................................12
Figure 2.6 Common Flange Dimensions........................................................................................................12
Figure 3.1 Common Vertical Installation.........................................................................................................14
Figure 3.2 Common Horizontal Installation.....................................................................................................14
Figure 3.3 OFS Mounting Hardware...............................................................................................................14
Figure 3.4 OFS TX/RX Overall Dimensions....................................................................................................15
Figure 3.5 Outdoor Control Box Mounting Dimensions...................................................................................16
Figure 3.6 OFS 19” Rack Mountable Control Box...........................................................................................16
Figure 3.7 Purge Air Detail.............................................................................................................................17
Figure 3.8 Rotameter (flow meter) .................................................................................................................17
Figure 3.9 "Natural" Air Purge........................................................................................................................17
Figure 3.10 Compressed Air Purge................................................................................................................17
Figure 3.11 Purge Air at 90° to Vertical Flow..................................................................................................18
Figure 3.12 Rotameter Installation.................................................................................................................18
Figure 3.13 Typical Gate Valve Installation ....................................................................................................19
Figure 3.14 Z-Purge Control Unit...................................................................................................................20
Figure 3.15 Control Unit Mounting Dimensions ..............................................................................................20
Figure 3.16 Typical Z-Purge Control Unit.......................................................................................................21
Figure 3.17 TX/RX Z-Purge Arrangement......................................................................................................21
Figure 3.18 Control Box Z-Purge Arrangement ..............................................................................................22
Figure 3.19 Transmitter AC Connections .......................................................................................................24
Figure 3.20 Control Box AC Connections.......................................................................................................24
Figure 3.21 User Interface Connections.........................................................................................................25
Figure 3.22 OFS2000FW Interconnects........................................................................................................26
Figure 3.23 Receiver Cable Connections.......................................................................................................26
Figure 3.24 TX AGC Cable Connection..........................................................................................................27
Figure 3.25 RX AGC Cable Connection.........................................................................................................27
Figure 3.26 TB3 Connections........................................................................................................................28
Figure 3.27 LDM Connection.........................................................................................................................29
Figure 3.28 Fiber Optic Modem Connection...................................................................................................30
Figure 4.1 Data Fields and Bytes...................................................................................................................35
Figure 4.2 Status Codes................................................................................................................................35
Figure 5.1 Connect PC to Controller ..............................................................................................................36
Figure 5.2 HyperTerminal setup steps ...........................................................................................................36
Figure 5.3 HyperTerminal Data Display..........................................................................................................37
Figure 6.1 Receiver "A" & "B" Lenses ............................................................................................................38
Figure 6.2 Receiver LEDs and Flow Direction................................................................................................38
Figure 6.3 OFS 2000FW TX Module..............................................................................................................39
Figure 6.4 OFS 2000FW RX Window.............................................................................................................39
Figure 6.5 Centering Light Beam ...................................................................................................................39
Figure 6.6 TX Rear View................................................................................................................................39
Figure 6.7 Receiver Window "Cat’s Eyes"......................................................................................................40
Figure 6.8 Transmitter Module.......................................................................................................................41

Optical Scientific Inc
OFS 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
v
Figure 6.9 Beam Centering............................................................................................................................41
Figure 6.10 Front Panel Display (example) ...................................................................................................41
Figure 6.11 Filter Material Insertion................................................................................................................42
Figure 8.1 Transmitter LEDs..........................................................................................................................44
Figure 8.2 Receiver LEDs..............................................................................................................................44
Figure 8.3 DSP Power LEDs..........................................................................................................................44
Figure 8.4 Correction Factor Display..............................................................................................................50
Figure 9.1 Window Cleaning..........................................................................................................................54
Figure 10.1 DSP Power Indicators.................................................................................................................57
Figure 10.2 DSP “Main Com ..........................................................................................................................57
Figure 12.1 Typical Thermal Activator Setup..................................................................................................61
Figure 12.2 Thermal Activator Dimensions.....................................................................................................62
Figure 12.3 Heater Wiring..............................................................................................................................63
Figure 12.4 Heater Schematic .......................................................................................................................63
Figure 12.5 OFS 2000FW and Thermal Activator Components......................................................................64
Figure 12.6 Thermal Activator........................................................................................................................65
Figure 12.7 Heater Thermocouple .................................................................................................................65
Figure 13.1 Typical Thermal Activator Setup..................................................................................................66

Optical Scientific Inc
OFS 2000FW User’s Guide
P/N 1910-901-1
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 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
1
1 OFS -2000FW 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
(indoor or outdoor)
Figure 1.1 OFS 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 -2000FW 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 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
2
1.2 OFS -2000FW Specifications
Flow Performance
Technique
Optical scintillation
Velocity Range
0.03 to 100 m/s velocity
Accuracy
2% of reading
Resolution
0.1 m/s
Response Time
User selectable: 3 sec to 600 sec
Long Term Drift
<1% >per year
Stack/Duct Diameter
2 –10+ Meters (6 - 30+ Ft.)
Media Temperature
No upper limit (for temp < 150°F an activator heater may be required)
(See Appendix A)
Light Source
670 nm red LED
Beam Divergence
5 degrees
Optics
Quartz window
(High temp sapphire glass available)
Purge
Purge fittings supplied
(Nominal recommendation is
4 CFM per system)
Factory-supplied instrument –grade purged air with 1-2 CFM
(optional) [See Section 3.4 “Purge Air”].
Maintenance
Calibration check
Automatic 2- or 3-point calibration check once per day or as requested by External Calibration
Check Request
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 (Outdoor components: TX/RX Heads, NEMA 4/4X Control
Box)
Ambient Temperature
-40 to 60 C
Dust Intrusion
IP65
Moisture
0-100% condensing
Data Output
Dual 4-20 ma optically isolated outputs --
Main Loop: Scalable; Auxiliary Loop: fixed 0-10m/s
Two relays for fault and calibration check indications
RS-232 ASCII, fixed data string - 2 types
Short with only velocity and P/F status
Long with all velocity and status data
- Optional Limited Distance Modem (LDM)
- Optional Fiber Optic Modem (FOM)
User Selectable with Integral Key Pad & Display including
Sensor ID Baud rate (9600 standard) Averaging Time Units of Measure
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
Physical Characteristics
Weight
TX & RXOptical Units
5 kg ea
Control Box (NEMA-4),
7 kg
Control Box (rack mount),
6 kg
Flange Adapter (spool piece) (2)
3 kg ea
Dimensions
TX & RXOptical Units
15 x 15 x 14 cm ea
Control Box (NEMA-4),
30 x 40 x 25 cm
Control Box (rack mount),
13x43x51 cm
Flanged Adapter (spool piece)
9-in. dia. (150# 4” ANSI bolt pattern on user end)
6-inch (15 cm) long
Materials
TX & RXOptical Units
Aluminum with powder-coat paint
Control Box
Aluminum with powder-coat paint (NEMA-4)
Steel and Aluminum (rack mount)
Adapter
Aluminum with powder-coat paint
Gate Valve (optional)
Cast Iron

Optical Scientific Inc
OFS 2000FW User’s Guide
P/N 1910-901-1
Rev. 03/28/13
3
1.3 Description of Units
The OFS -2000FW model has three main elements:
Transmitter (TX) Unit [1910-100-1]
Receiver (RX) Unit [1910-200]
Control Box [1910-301 outdoor / 1910-500 indoor (rack-mount)]
The TX and RX Units use identical packaging to house the optical and electronic subsystems. All parts are
made from powder-coated aluminum, and are weather tight. Both housings have holes for standard 1/2”
electrical fittings for cable or conduit. 1/4” NPT fittings are provided for low-pressure air if internal
pressurization is required.
Note: Both TX and RX units are supplied with integral “spool piece” flange adapters. These adapters provide
isolation and are equipped with purge air fittings to keep the light path clear.
There are two types of Control Box –Outdoor and Rack Mount. The box houses the DSP processor, power
supply, and interface components. The Box is connected to the RX Unit via a shielded cable (P/N 1910-217)
supplied with the OFS. The Outdoor Control Box meets NEMA-4 standards. It has nominal 1-inch diameter
holes for the user to make power and signal/communications connections. The rack-mount Control Box has a
power cord socket and a terminal block for the user to make signal/communication connections. The user
supplies power and communication cables. The use of 1/2-inch flex conduit is recommended to protect the
wiring from the harsh industrial environment.
Figure 1.2 OFS 2000FW System Components