I N S T R U C T I O N M A N U A L R E V 4 . 2
OPM4001 Opacity/Dust Density Enhanced
Controller Installation and Operation
Manual
I N S T R U C T I O N M A N U A L R E V 4 . 2
CO N T ENT S
TECHNICAL SUPPORT HOTLINE ............................................................................................................................................ 4
SECTION 1 SYSTEM DESCRIPTION ........................................................................................................................................ 5
Transmissometer /retro reflector ................................................................................................................................. 5
RCU............................................................................................................................................................................. 7
Optional Air Purge Weather Cover System ................................................................................................................... 7
Alignment system........................................................................................................................................................ 7
Cabling ....................................................................................................................................................................... 7
SYSTEM SPECIFICATIONS ........................................................................................................................................................ 8
SECTION 2 INSTALLATION CONSIDERATIONS ..................................................................................................................... 10
Before start up .......................................................................................................................................................... 10
Environment ............................................................................................................................................................. 10
MOUNTING THE AIR PLENUM AND WEATHER COVERS................................................................................................................... 11
Transceiver and retro reflector assembly ................................................................................................................... 12
Beam alignment procedure ....................................................................................................................................... 13
Air flow switch .......................................................................................................................................................... 14
Control unit ............................................................................................................................................................... 14
SECTION 3 BEFORE START UP ............................................................................................................................................ 15
STACK EXIT CORRELATION COMPUTATION ................................................................................................................................. 15
SECTION 4 CONTROL UNIT PAGE DESCRIPTION.................................................................................................................. 16
CONTROL UNIT SCREENS ....................................................................................................................................................... 16
General page layout .................................................................................................................................................. 16
Control unit Glossary of terms ................................................................................................................................... 17
Company information page ....................................................................................................................................... 18
Home Page ............................................................................................................................................................... 18
Clean screen .............................................................................................................................................................. 18
Calibration Page ........................................................................................................................................................ 19
Fault Page ................................................................................................................................................................. 19
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I N S T R U C T I O N M A N U A L R E V 4 . 2
Settings Page ............................................................................................................................................................ 20
Operator Setup ......................................................................................................................................................... 21
Tech Setup and Backup/Restore ................................................................................................................................ 21
Set Local Time and Date ............................................................................................................................................ 24
Change Passwords .................................................................................................................................................... 26
Diagnostics Page ....................................................................................................................................................... 27
Alarm Page ............................................................................................................................................................... 28
Display Page ............................................................................................................................................................. 29
About Page ............................................................................................................................................................... 30
SECTION 5 MODBUS AND ANALOG OUTPUTS .................................................................................................................... 31
MODBUS ADDRESS INFORMATION .......................................................................................................................................... 31
RS/485 COMMUNICATIONS AND CONNECTION ......................................................................................................................... 33
ALARM RELAY DESCRIPTIONS ................................................................................................................................................. 34
ANALOG OUTPUT CONNECTIONS............................................................................................................................................ 35
Output Channels #1, 2, 3 and 4 .................................................................................................................................. 36
4-20MA .......................................................................................................................................................................... 36
SERVICE MODULE ............................................................................................................................................................... 37
SECTION 6 CLEAR PATH ADJUSTMENTS ............................................................................................................................. 38
Clear on stack zero and span calibration .................................................................................................................... 38
Zero reflector adjustment .......................................................................................................................................... 39
Span filter value ........................................................................................................................................................ 40
Record the zero/span values ...................................................................................................................................... 40
Off stack zero calibration ........................................................................................................................................... 40
SECTION 7 MICRO-TURN AUDIT KIT ................................................................................................................................... 41
USING THE ON LINE ZERO REFLECTOR (OPTION) .......................................................................................................................... 41
FILTER CORRECTION FORMULA ............................................................................................................................................... 42
SECTION 8 PREVENTIVE/CORRECTIVE MAINTENANCE ....................................................................................................... 43
Preventive/corrective maintenance schedule ............................................................................................................. 43
Trouble Shooting ....................................................................................................................................................... 46
Trouble shooting -continued ...................................................................................................................................... 47
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I N S T R U C T I O N M A N U A L R E V 4 . 2
SECTION 9 SPARE PARTS .................................................................................................................................................... 48
SECTION 10 DRAWINGS ..................................................................................................................................................... 50
OPM6127 1OF3 – CONTROL UNIT TO SENSOR WIRING/DUAL BLOWER................................................................................... 51
OPM6127 2OF3 – CONTROL UNIT TO SENSOR WIRING /SINGLE BLOWER ................................................................................ 52
OPM6127 3OF3 – CONTROL UNIT TO SENSOR WIRING /NO BLOWER ..................................................................................... 53
RS485: Pin out ........................................................................................................................................................... 54
SECTON 11 ALARM MATRIX ............................................................................................................................................... 55
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I N S T R U C T I O N M A N U A L R E V 4 . 2
TECH NI CAL SUPPORT H O TLINE
For assistance with problems, please call the Customer Support Center (CSC).
Phone: 1-800-433-6076 1-440-914-1261
In addition to CSC, you may also contact Field Watch. Field Watch coordinates Emerson Process Management’s field
service throughout the U.S. and abroad.
Phone: 1-800-654-RMST (1-800-654-7768)
Emerson Process Management may also be reached via the Internet through e-mail and World Wide Web:
E-mail: GAS.CSC@emerson.com
World Wide Web: www.raihome.com
Warnings and Safety Guidelines for user safety and equipment protection.
This manual is intended to aid trained and competent personnel in the installation of this equipment. Only a technician or
engineer trained in the local and national electrical standards should perform tasks associated with the electrical wiring of
this device.
WARNINGS
UNDER NO CIRCUMSTANCES WILL EMERSON PROCESS MANAGEMENT BE LIABLE OR RESPONSIBLE FOR
ANY CONSEQUENTIAL DAMAGE THAT MAY ARISE AS A RESULT OF INSTALLATION OR USE OF THIS
EQUIPMENT.
ALL EXAMPLES AND DIAGRAMS SHOWN IN THE MANUAL ARE INTENDED TO AID UNDERSTANDING. THEY
DO NOT GUARANTEE OPERATION.
EMERSON PROCESS MANAGEMENT ACCEPTS NO RESPONSIBILITY FOR ACTUAL USE OF THIS PRODUCT
BASED ON THESE EXAMPLES.
DUE TO THE GREAT VARIETY OF POSSIBLE APPLICATIONS FOR THIS EQUIPMENT, THE USER MUST ASSESS
THE SUITABILITY OF THIS PRODUCT FOR SPECIFIC APPLICATIONS.
MAKE SURE TO HAVE SAFETY PROCEDURES IN PLACE TO STOP ANY CONNECT3ED EQUIPMENT IN A SAFE
MANNER IF THE CONTROLLER SHOULD MALFUNCTION OR BECOME DAMAGED FOR ANY REASON.
DO NOT REPLACE ELECTRICAL PARTS OR TRY TO REPAIR THIS PRODUCT IN ANY WAY.
ONLY QUALIFIED FACTORY TRAINED SERVICE PERSONNEL TRAINED IN ITS OPERATION SHOULD OPEN THE
DEVICE’S HOUSING OR CARRY OUT REPAIRS.
THE MANUFACTURER IS NOT RESPONSIBLE FOR PROBLEMS RESULTING FROM IMPROPER OR
IRRESPONSIBLE USE OF THIS DEVICE.
You may cause an electric shock, fire or damage the equipment if you ignore any of these safety precautions.
4
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 1 SYST EM DES CRIPT I O N
TR A NSMISSOMETER /R E TRO REF L EC T OR
The OPM4001 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.
NORMAL MODE OF OPERATION
The Dual beam measurement system has a stack mounted Transmissometer sensor system consists of an optical transceiver
mounted on one side of the stack and a retro reflector mounted on the other. To avoid errors due to ambient light, the wide band
lamp (See Drawing) 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 Transmittance 2 (T
2
) 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 (T 2) signal 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, provide alarms and outputs.
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I N S T R U C T I O N M A N U A L R E V 4 . 2
INTERNAL CALIBRATION SYSTEM, ZERO MODE
Zero and span calibration checks can be initiated manually, automatically or by a PLC or computer. During the zero calibration mode
a calibrated zero reflector is placed in front of the transceiver optical package testing all optical surfaces and electronic components
to assure zero point has not changed.
INTERNAL CALIBRATION SYSTEM, SPAN MODE
In the span mode a Span filter of known Neutral Density is placed in the measurement path and produces a specific upscale reading
in accordance with the latest E.P.A. requirements. The zero and span cycle provides a continuous check of all the optical
components and surfaces, the main lamp, the detector, interconnecting wiring, control unit and computation analysis.
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I N S T R U C T I O N M A N U A L R E V 4 . 2
RCU
The RCU provides instrument control functions, opacity readings, alarms, analog outputs,
communications, system information and more. The color 5x7” viewing screen can be seen in
low light levels and bright. The RCU is rated NEMA 4X/IP65 when panel mounted. Battery backup
for all memory is typically 7 years.
The control unit should be mounted in a control room environment i.e., clean, temperature with
max/min of +0o to +50 o C (+32 o to + 122 o F). The OPM4001 ENHANCED control unit provides
instrument control functions, opacity readings, alarm and fault indicators, analog outputs, and
diagnostics with contact closures.
OP TI ON AL AIR PUR G E W EATHER CO VER 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 air flow is directed
through the hose to an air plenum on the stack side of the optical window. The air flow in the air
plenum area results in reduced 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 OPM4001 ENHANCED 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 a minimum 6-pair, #20 AWG, twisted,
shielded. Separation distances approximately 1000FT, more pairs or larger gage than 20 AWG is also acceptable.
7
REMOTE CONTROL UNIT:
Enclosure
Panel mounted IP65/NEMA4X Dimensions: 197X146.6X68.5mm (7.75" X 5.77"
X2.7").
Approvals
CE and UL Listed
Digital Display
LED backlight, Instant and Average Opacity -5 to 99% Opacity
Ambient Temperature Range
0 to +50o C (+32 to + 122o F)
Power Requirements
Power 20.4 to 28.8VDC < 10% ripple, 20va
Alarm Time Delay & set point
Field programmable.
Alarm Reset
Manual or Automatic
Analog Outputs (4)
Four 12-bit Analog outputs 4-20mA, Field selectable range -5.0 to 100%.
Ch1 and Ch2 Individually field selectable for Instant % opacity, or 6 minute
average with z/s checks or without checks for process control.
Exit Correlation (Lx / Lt)
0.3~1.0 OPLR
Calibration check options
Selectable internal timed or computer initiates or push button on demand.
Communication
Remote access, RS485 MODBUS networking.
Battery Backup
7 years typical
I N S T R U C T I O N M A N U A L R E V 4 . 2
SYS T EM SPECIFI C ATION S
8
TRANSCEIVER/ REFLECTOR:
Enclosure/Power Requirements
NEMA 4X. Power 120 or 240VAC +/- 10%, 50/60Hz. 65va for
transceiver, 65va for Service module.
Path Length
2 to 50 feet (0.6 to 4.6 15.2 meters)
Optical System
Double Pass with Wide band source, Electronic Modulation. USDEP
40 CFR 60 appendix B, PS-1 and ASTM D 6216 specifications.
Ambient Light Immunity
Wide band source, Electronic Modulation. USDEP 40 CFR 60
appendix B, PS-1 and ASTM D 6216 specifications.
Reflector
Type 1 (plastic) reflector assembly, long path Glass.
Alignment Verification
Built-in through-the-lens system standard
SOURCE Aging Compensation
Automatic
SOURCE Expected Life
70,000 hours (Field proven for > 8 years)
Ambient Temperature Limits
-40 to +130o F (-40 to +54o C)
Process Gas
Up to 750o F (400 o C) higher available contact the factory.
Mounting Flanges
3 inch IPS, 150# flange (other sizes available)
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. USDEP 40 CFR 60 appendix B,
PS-1 and ASTM D 6216 specifications.
Angle of View
<4.0 o from optical axis
Angle of Projection
< 4.0 o from 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
I N S T R U C T I O N M A N U A L R E V 4 . 2
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I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 2 INSTAL LA T ION CONS ID ER A TIONS
BEF OR E START UP
You must complete the following before start up is attempted.
Measure and record flange -to-flange distance to verify it is the same as final check out sheet.
If you are using a recorder, DAS, etc., DO NOT CONNECT THEM NOW. Outputs and inputs from other sources should be left off until
system has been completely checked according to the following instructions. After system operation has been verified connect and
test external connections.
Read the instructions first to familiarize yourself with the instrument before attempting start up.
The air purge and Weather cover system, Transceiver, Retro reflector, Service module must be installed and power applied.
Control unit must be installed and wired to the service module and customers equipment as applicable.
All wiring and mechanical installations must be complete per drawings provided in this manual. All wiring must be checked and
power applied to both the control unit and the stack maintenance module.
Beam Alignment procedure has been completed.
EN VIRONMENT
Locate the control unit in an easily accessible area with temperatures between +32o to 122o F. To permit the operator to read
and/or change controls, the unit should not be mounted higher than five feet from floor level.
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I N S T R U C T I O N M A N U A L R E V 4 . 2
MOU NTING THE AIR PL ENUM AN D W EATHER COVE RS
WARNING! CONTROL UNIT, TRANSCEIVER & RETRO SERIAL NUMBERS MUST
MATCH.
After the installation site has been selected and the platform requirements have been met, the mounting flanges should be installed
and aligned as described on Drawings OPM6130 and 6131. Flanges should be installed with the mounting faces on the vertical plane.
1) Before installing the Transceiver, Retro reflector or any type of
weather cover remove the air plenum from both the Transceiver
and retro reflector. Removal will make the installation easier and
less chance of damage while mechanical attachment of the air
plenums and optional weather covers when provided.
2) If the transceiver and retro reflector have been shipped from the
factory with the air plenum attached, un-clip both hold down
latches, swing open and lift up & off the hinge pins. Place the
Transceiver and retro in a safe place.
3) The air plenum is attached to the customer supplied 3" pipe flange
by four 2 1/2" long 5/8-11 bolts. Working from the 3" flange the
correct assembly is: gasket then air plenum.
4) If you have weather covers remove the two (2)-weather cover hood hinge pins located on the upper right and left
hand corner of the hood. The air plenum and weather cover are attached to the 3" pipe flange by four (4) 2 1/2"
long 5/8-11 bolts. Working from the 3" flange the correct assembly is; gasket, weather cover mounting plate,
gasket, mating flange & air plenum. Place the 5/8-11 bolt through the top hole of the middle plate. Place a flat
washer between the middle plate and mating flange and pass the bolt through. Slip a split lock washer over the
bolt and secure with a nut.
Repeat for the remaining
three mounting bolts.
5) Any wiring or air hoses can be
connected now.
11
I N S T R U C T I O N M A N U A L R E V 4 . 2
TR A NSCEIVER AND RE TR O REFLEC T OR ASSEMBL Y
6) Attach the Transceiver and Retro reflector to the
air plenum assembly by placing them on the hinge
pins.
7) Close transceiver & retro and secure in place with
the two hold down latches.
8) The air-purge blowers should be powered up at
this time to prevent stack particulate from
accumulating in the nipple and air-purge housing.
Caution: If installed location has a positive pressure the air-purge system must be used continuously during installation to prevent
process gases from contaminating optical surfaces or over heating instrument electronics. If the system is shut off for more than
momentary interruptions, the instrument may be damaged. Failure to provide continuous air-purge may void the warranty.
All wiring from the control unit to the transceiver should be completed at this time.
NOTE: THE AIR PLENUM ASSEMBLY FOR BOTH TRANSCEIVER AND RETRO MUST BE INSTALLED AS BELOW, I.E. THE PINS ON
THE LEFT SIDE POINTING UP!
12
I N S T R U C T I O N M A N U A L R E V 4 . 2
BEAM ALIG NME N T P R O C E DUR E
Note: Alignment cannot be done unless the power is applied to the stack mounted service module. The control unit does not have to
be connected or powered. For alignment accuracy, the stack should be at normal temperature.
MAINTENANCE MODULE SWITCHES SHOULD BE IN THE NORMAL OPERATING POSITIONS:
Zero/Operate - Operate
Span/Operate - Operate
Normal/Test - Normal
through the viewing port located on the rear of the transceiver and observing whether the beam image is in the
center of the cross hair (bulls-eye).
Opacity/T
2
- Opacity
9) If not already on, turn on the power to all air purge systems and service
module.
10) Align the Reflector mating flange so it is plumb and parallel to the 3" 150#
mounting flange. Use the 3 adjusting nuts on the air purge plenum flange until this is
accomplished. The adjusting nuts have nylon locking inserts to prevent loosing by vibration.
11) Move to the Transceiver, and determine monitor alignment by looking
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I N S T R U C T I O N M A N U A L R E V 4 . 2
AIR FLOW SWITCH
If you have an airflow alarm when the system is powered check the airflow switch. With the blower running and the source under
normal conditions disconnect the leads of the switch and place an ohmmeter across them. The switch should be closed, less than 2
ohms, if flow is enough to overcome stack pressure and blower inlet is clear. Cover the air cleaner inlet and verify the switch opens.
Replace the leads the test is complete.
CONTROL UNI T
Mount the control unit at eye level for best viewing of the display.
Cut out for panel mounting is shown in the drawing section. Insert the control unit through the cut out hole. Insert the panel
mounting hardware in the slots provided on each side of the control unit from the rear. Tighten the screws until the control unit is
securely held in place.
Wire the control unit per drawing section and Energized power.
NOTE: CONTROLLER REQUIRES 24VDC.
5.7" 256-Color Touch panel, QVGA TFT display (or CSTN), 197X146.6X68.5mm (7.75" X 5.77" X2.7")
Display ‘touchable’ images, text and graphs according to real-time conditions and historical values
‘Touch’ properties can be assigned to all text and graphic on-screen elements
Data entry/modification via keypad
LCD illuminated screen
Virtual keyboard
Info mode: view/modify I/O status, integer values, and system data via the
panel
14
Lt
Lx
OPLR*2
50.0
120*2
120
OPLR
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 3 BEFOR E S TART UP
You must complete the following before start up is attempted.
Check that all parts have the identical serial numbers.
Measure and record flange -to-flange distance to verify it is the same as final check out sheet.
If you are using a recorder, DAS, etc., DO NOT CONNECT THEM NOW. Outputs and inputs from
other sources should be left off until system has been completely checked according to the following instructions.
After system operation has been verified connect and test external connections.
Read the instructions first to familiarize yourself with the instrument before attempting start up.
The air purge and Weather cover system, Transceiver, Retro reflector, Service module must be installed and
power applied.
Control unit must be installed and wired to the service module and customers equipment as applicable.
All wiring and mechanical installations must be complete per drawings provided in this manual. All wiring must be
checked and power applied to both the control unit and the stack maintenance module.
Beam Alignment procedure has been completed.
STA CK EXIT CORR ELA TI ON C OMP U TA TION
The stack exit correlation is especially important to verify. If possible all dimensions should be verified by actual measurements.
Measure and record inside stack dimensions at the measuring point and at the stack exit, and compute the Optical Path Length Ratio
(O.P.L.R.). Verify that the calculated and the value of O.P.L.R. found in the About page are within +/- 2%.
Lx = Stack exit inner diameter, Lt = Inner diameter of the effluent path
Example: A stack with a 120" stack exit I.D. and a 120" path length
15
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 4 CONTRO L U NIT PAGE D E S CRIPTION
CONTROL UNI T SC R EEN S
GEN ER AL PAGE LAY OU T
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I N S T R U C T I O N M A N U A L R E V 4 . 2
CONTROL UNI T GLOS S A RY OF TER MS
OUTPUT TYPE SETUP – “Output type” refers to the 4-20mA outputs.
Instant opacity, z/s outputted during cal cycle.
Average, 6 minute opacity average z/s outputted during cal cycle.
Last - instant opacity, last value is held during cal cycle.
Note: Last should be used if you are using the output for process control signal.
ALARM AUTO/MANUAL SETUP – Press return/enter button to enter. Choose between 1-auto or 2- manual.
Auto means when the high opacity alarm has been activated and when the level of smoke drops below the alarm point the
alarm contacts 02 & 04 and icon will reset automatically.
Manual reset means when the high opacity alarm has been activated, pushing the return/enter button 04 contact will de-
energize but 02 will remain energized. When the level of smoke drops below the alarm point the return/enter button is
pushed and both 02 &04 will be de-energised.
OUTPUT SCALING SETUP – Press return/enter button to enter.
Set Ch 1 or 2 to desired opacity range i.e, for 4ma to represent minimum opacity and 20mA to represent maximum
opacity. The 20mA value of 99.9 is used to represent 100%.
Note; For CFR 40, PS-1 the set 4mA to -5% To get negative values press +/- once for negative then button 5 then +/-
again for the decimal placement. i.e, Ch.1 4 mA: -5.0 % 20mA: 99.9%
MODBUS I.D. SETUP – Press return/enter button to enter and input the node number (1 to 32) desired press Press
return/enter button to to set then ESC to exit.
17
When power is first applied the company info page is
displayed. Wait a few seconds and the Home page will
appear. Or touch “LOGO and it will immediately go to
the Home page.
Touch the icon to go to the sections.
Calibration
Fault
Alarms
Settings
Displays
Diagnostics
About
I N S T R U C T I O N M A N U A L R E V 4 . 2
COMPANY INFORMATI ON PAGE
HOME P A GE
CLEAN SCREEN
To clean the screen press the clean screen icon on the home page, green blank page will come in to view with a countdown clock
starting at 10 seconds. Use appropriate cleaner and cloth to clean this screen. When done it will automatically return to the home
screen.
18
Touch the Cal Icon on the home page. Initiate a Z/S
check by pressing the Green Manual Cal Initiate button
(It will turn Yellow). The zero is 3 minutes and span is 3
minutes long for calibration cycle of 6 minutes. The
Right column will show In Zero and at about 30 seconds will update the
Green Pass or the Red Fail icon. The values are entered at set up in the
tech screen under “Zero cal value, Span Cal Value". If these values are
within +/- 2% Opacity the green Pass will be shown, If it is not it will
show Red Fail and trigger the fault system. Fail will remain in memory
until after the values are corrected and another cal is initiated.
The current opacity and window dust is displayed below for your
convenience. The system will automatically return to monitoring the
process at the 6 minute point from cal start. You will know this because
the Manual Cal Initiate icon will return to Green. It is not necessary to
stay in this screen after initiation and recommended to return to the
screen normally displayed.
Acknowledge Fault button: when in fault pressing the Ack button
will temporarily open the fault contact 14.
After time limit (set in tech screen 4: default 1 minute) if any
fault is showing the relay will close, energize. If all faults are
cleared the relay will auto reset to open, de-energize.
I N S T R U C T I O N M A N U A L R E V 4 . 2
CALIBRATI ON P AGE
FAULT PAGE
19
From the Home Touch the Settings icon to get to this
page.
For Operator setup press the button, and enter the
default password 1111 when indicated and press return
arrow.
For Tech setup press the button, and enter the default
password 1234 when indicated and press return arrow.
I N S T R U C T I O N M A N U A L R E V 4 . 2
SET TINGS PAGE
20
All raised buttons can be touched and values changed.
All flat buttons are read only.
The opacity and mg alarms can be turned on or off by
touching the appropriate alarm.
All raised buttons can be touched and values changed.
Instructions are on the bottom of the screen when
required.
All flat buttons are read only.
I N S T R U C T I O N M A N U A L R E V 4 . 2
OP ER ATOR SETUP
TEC H SETUP AN D BA C KU P / RESTO R E
21
All raised buttons can be touched and values changed.
Instructions are on the bottom of the screen when
required.
All flat buttons are read only.
Cal time is in 24hr clock format.
Note: If in internal the clock will control the cycle.
While in external the internal clock is disabled and only
an external input will activate the cycle.
Clone backup/restore
If not already there, Enter SD Password: 123
Backup: After startup is complete and all controller
changes are made, enter a new file name with 8
characters and/or numbers only, no more, no less.
Touch “Backup PLC -> SD” System backup all
changes to the S.D. card.
Restore: to restore put the name of your backup
and touch “Restore SD -> PLC. This will take several
minutes to complete the backup.
I N S T R U C T I O N M A N U A L R E V 4 . 2
22
All raised buttons can be touched and values changed.
Instructions are on the bottom of the screen when required.
All flat buttons are read only.
I N S T R U C T I O N M A N U A L R E V 4 . 2
23
I N S T R U C T I O N M A N U A L R E V 4 . 2
SET LOC AL TIME A N D D ATE
To set to local time touch and hold any part of the Yellow back ground until Info Mode appears.
1. Touch “Enter Info Mode” at Enter Password page, enter 1111, and touch the return button.
2. Touch “Time & Date” button.
3. Enter the “Date” dd/mm/yy.
4. Enter the time in 24hr hh:mm: ss. Press ESC until Tech page returns.
24
All raised buttons can be touched and values changed.
All flat buttons are read only.
All raised buttons can be touched and values
changed. Instructions are on the bottom of the
screen when required.
All flat buttons are read only.
I N S T R U C T I O N M A N U A L R E V 4 . 2
25
Only the tech can change passwords the default for
Operator is (1111) and for Tech (1234). To change
passwords touch raised button and enter new password
(up to 8 numbers are provided).
The tech can reset to default value by holding the reset
button for 3 seconds.
CRITICALLY IMPORTANT!
THE TECH (GATEKEEPER) OF THE CONTROL UNIT AT HIS
DISCRETION CAN CHANGE BOTH PASSWORDS;
HOWEVER IT IS CRITICAL THAT THE PASSWORD IS
SECURED AGAINST LOSS. IF GATEKEEPER’S PASSWORD
IS LOST CONTACT THE FACTORY FOR PROCEDURE TO
RESET TO DEFAULT SETTINGS.THIS PROCEEDURE IS IN
PLACE TO PROTECT THE INTEGRITY OF THE DATA
COLLECTED AND THE OPERATION OF THE UNIT.
I N S T R U C T I O N M A N U A L R E V 4 . 2
CHANGE PA S S W OR D S
26
Touching the Controls button for control page requires
the tech password.
WARNING: pre-set returns all selections to default. Do
not use unless instructed by Rosemount service
engineer.
Touch the Relays button in the sub menu for conditions
of the relays to be checked, relay # is de-energized if
gray energized if green.
Touch the Digital in the sub menu button, or the right
arrow for checking input conditions. Inputs are gray if
NO input, RED if input is active.
I N S T R U C T I O N M A N U A L R E V 4 . 2
DI AGNOSTICS PA G E
These pages are intended to be used by Rosemount Factory trained technicians and detailed explanation of their use is not in the
scope of this manual.
27
The count reset clears the alarm count column.
Alarm Relay Auto/Manual operation default is Auto (automatic). To
change it selected in the operator control page. See Appendix B for
alarm relay matrix.
Auto/Manual
select.
I N S T R U C T I O N M A N U A L R E V 4 . 2
ALARM PAGE
28
Touch the buttons to go to the display of interest.
Pages are:
1. Instant Opacity
2. 6 minute Average Opacity
3. Split opacity screen (Instant/Average)
4. Dust (mg/m3)
5. Optical Density
6. Op/Ave Trend (Red= Ave, Blue= Instant)
7. Dust Trend. Dust max scale can be changed by
touching the scale button and entering the F.S
(do not exceed 2000).
Set F.S. here
I N S T R U C T I O N M A N U A L R E V 4 . 2
DI SPLAY PAGE
29
About page displays the basic setup information.
I N S T R U C T I O N M A N U A L R E V 4 . 2
ABOUT PAGE
30
Read:
0% to 99.9% instantaneous opacity
MI 230
181 = 18.1%
0% to 99.9% average opacity
MI 231
182 = 18.2%
O.D. 0-2.0
MI232
2000 = 2.0 O.D.
Mg 0-2000
MI 233
20000 = 2000mg
Window dust
MI 234
0-10%
Relay 02 Zero to SM (6)
MB 230
Zero, not cal = 0, in cal =1
Relay 03 Span to SM (3)
MB 231
Span, not cal = 0, in cal =1
Relay 08 DAS in cal (6)
MB 232
Zero, not cal = 0, in cal =1
Relay 09 DAS in Zero (3)
MB 233
Zero, not cal = 0, in cal =1
Relay 10 DAS in span (3)
MB 234
Span, not cal = 0, in cal =1
Relay 11 (High alarm) [Mg]
MB 235
No alarm =0. Alarm =1
Relay 12 (High alarm) [OP]
MB 236
No alarm =0. Alarm =1
Relay 13 (High alarm Audible) [OP &
Mg]
MB 237
No alarm =0. Alarm =1
Relay 14 (Fault)
MB 238
No fault =0. Fault =1 (See
fault list in manual)
Relay 15 (Opacity EW)
MB 239
No alarm =0. Alarm =1
Relay 16 (mg EW)
MB 240
No alarm =0. Alarm =1
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 5 MODBUS A N D ANALOG O U T PUTS
MODBU S A DDRESS IN F O R MATI ON
MB = Modbus Poll Read Discrete inputs (10001….20000)
MI = Modbus Poll Read Holding (4001…50000)
31
Read; Common fault individual blocks:
In maintenance
MB 241
In Maint. =0, Not In Maint. =1
SM Power status
MB 242
Lost power to SM=0, Power OK =1
T2 Signal lost/low
MB 243
Signal OK =0, Lost signal =1
Negative opacity
MB 244
Positive opacity =0, Negative Opacity
=1
Zero Cal Fail
MB 245
Fail =1, Not fail =0
Span Cal Fail
MB 246
Fail =1, Not fail =0
No Air flow (Modbus only)
MB 247
OK =0, Not OK =1
Cal cycle
MB 248
Off = 0, On = 1
Read/Write:
Remote Cal. Initiate
MB 249
Initiate cal =1
Alarm Set point [OP]
MI 235
(Format: 1 - 100)
Alarm Set point [Mg]
MI 236
5000 =500
Alarm delay
MI 237
(Format: 1-360 seconds)
Early Warning Set point [OP]
MI 238
(Format: 1 - MI 236)
Early Warning Set point [Mg]
MI 239
900 = 90
Early Warning delay
MI 240
(Format: 1-360 seconds)
I N S T R U C T I O N M A N U A L R E V 4 . 2
32
I N S T R U C T I O N M A N U A L R E V 4 . 2
RS/485 COMMUNI C ATIONS A N D C ONNECTION
Port 2, 6-pin R J25 connector Pin 1 (+), Pin 6 (-). RS-485 cabling may be up to 2000 feet in length. Belden P/N 3106A cable is
recommended. Note: Cable drawing and pin out at the end of drawing section.
If not specified in the original order default is as follows. NOTE: The following communication parameters cannot be changed in the
field the controller must be returned to the factory.
Baud Rate: 9600
Data Bits: 8
Parity: None
Flow Ctrl: None
Timeout: 0.2 seconds.
33
OPM4001 ENHANCED Relays
Group 1 Relays
(Zero solenoid to SM) 02
(Span solenoid to SM) 03
Group 2 Relays
In CAL to DAS (6 Minutes) - 08
Zero solenoid command contact (3 Minutes) - 09
Span solenoid command contact (3 Minutes) - 10
High mg Alarm - 11
High Opacity Alarm - 12
High Opacity/mg Alarm Silence - 13
Fault relay, Normal=0;Fault on When = 1 - 14
Early warning Hi mg - 15
Early warning Opacity - 16
COM for Relays 08-16
I N S T R U C T I O N M A N U A L R E V 4 . 2
ALARM RELAY DESC R I PTIONS
Alarm outputs are SPST relays. Relays are rated at: 30Vdc, 3Amp max per relay and 8Amp max per common. Common for Relays 0816 should not be connected to other commons on the controller.
34
I N S T R U C T I O N M A N U A L R E V 4 . 2
ANALOG OUTPUT CONN EC TIONS
35
OPM4001 ENHANCED Analog output
wiring list wiring list
Common for mA outputs - ACM
Positive 4-20mA output CH1 - Aout0
Positive 4-20mA output CH2 - Aout1
Positive 4-20mA output CH3 - Aout2
Positive 4-20mA output CH4 - Aout3
I N S T R U C T I O N M A N U A L R E V 4 . 2
OU TP UT CHA N NELS # 1, 2, 3 A N D 4
4- 20 MA
The OPM4001 ENHANCED comes with four, 4-20mA output channels. The ranges are set during factory testing to the information
supplied by the customers. Field changes can be made in the set up page. Maximum output Loop compliance is 500 Ohms.
Channel 1 Is dedicated to the Service Module display with F.S. -5 to 99.9% opacity.
Channel 2, 3 and 4 can be used for DAS, recorder etc. To utilize the current loops (max 500 ohms total). F.S. ranges are customer
selected.
36
I N S T R U C T I O N M A N U A L R E V 4 . 2
SER V I CE MODULE
The service module is used to pass signals to and from the transceiver and control unit and display opacity via digital meter, initiate
maintenance zero and span cycles and insertion of external current meter in the transceiver to control unit 4-20mA loop.
OPACITY / T2 - This switch selects the display of the stack digital meter. In the Opacity
mode the digital displays % Opacity from the control unit. In the T2 mode it is the signal
out of the transceiver in % Transmittance 2.
OPERATE / ZERO - This switch controls the zero mirror solenoid. In the operate position
the mirror is not in the measuring path and is considered normal operation. When the
mirror solenoid is energized the mirror is placed in the measurement path and is
considered a maintenance condition, i.e. signal is not representative of the stack smoke.
The control unit will indicate a Fault.
Energizing and observe the digital meter to test the systems response to
zero % opacity.
Energize in conjunction with the span filter to observe the upscale span % opacity calibration point.
OPERATE / SPAN - This switch controls the span filter solenoid. In the operate position the span filter is not in the measuring path
and is considered normal operation. When the span filter solenoid is energized the span filter is placed in the measurement path and
is considered a maintenance condition, i.e., signal is not representative of the stack smoke. The control unit will indicate a Fault.
Energize in conjunction with the zero mirror to observe the upscale span calibration point.
NORMAL / TEST - This switch controls the EXTERNAL mA METER connections. In the normal mode the terminals are shorted. In the
test mode the terminals are open and the current loop from the transceiver is interrupted allowing the use of an external current
meter to be placed in series with the transceiver current output. When this is in the test mode position it is considered a
maintenance condition and fault condition. If no current meter is in the test jacks the loop current the control unit will indicate full
scale and the control unit will indicate a Fault.
37
PCB 1667 (p/n 1A99993H03 for
replacement)
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 6 CLEAR PA T H ADJUST M E NTS
CLEAR ON STACK Z ER O AN D SP A N CALIBRA T I ON
A clear stack condition must exist to perform this calibration. Power must have
been on for no less than 30 minutes. Do not attempt these adjustments in
inclement weather. After the cover is removed from the transceiver normal
levels of day light in the area will not affect the calibration.
To complete this procedure the following items are required: Audit device
Micro-turn 200 on-line test kit (p/n 1A99993H24) with a high filter of at least
0.8 O.D.
1. Swing both the retro and transceiver open and clean the protective
windows. Return both to the closed position.
2. Verify alignment, returning beam is centered on the TTL target.
3. On the transceiver remove the screw below the target viewing
window and pulling the housing straight back until it clears the optical
plate.
4. On the Service Module make sure the normal/test switch is in the
normal position.
5. NOTE: All adjustments are on the 222-1667 PC Board (p/n
1A99993H03 for replacement).
6. Adjust the 20 turn Zero potentiometer on board 222-1667 (p/n
1A99993H03 for replacement) marked "PT -1", CW for an upscale
reading >15%, then slowly CCW for 0-1% opacity.
7. Install the Micro-turn 200 on-line test reflector on the transceiver and
screw the device to the transceiver with the mounting screw. With
the thumbwheel adjust the on-line reflector for the same opacity as in previous step and lock it in place.
8. Place the highest value filter (for best results at least a 0.8 O.D.) in the slot provided. Adjust the Span potentiometer on
board 222-1667 (p/n 1A99993H03 for replacement) marked "PT -3" for the filters correlated value on the service
module opacity display equals to the correlated value. See section six (6) for filter correlation formulas.
9. Remove the filter and adjust the Zero potentiometer PT-1 for 0-1%.
10. Insert the High filter again adjust PT-3 for its value, repeat steps until the values come within 0.5 % Opacity.
11. Remove the on-line test reflector and replace the transceiver cover and secure the transceiver in place. You must
complete "Zero Reflector Adjustment" procedure next.
38
I N S T R U C T I O N M A N U A L R E V 4 . 2
ZERO R EFLECTOR A D J USTMENT
After a clear or off stack zero has been performed the zero reflector needs to be adjusted.
1. Find and record the zero offset value found in the set
up page under "Zero Cal Value".
2. On the service Module place the Opacity/ T2 switch
in the Opacity position to observe the correlated
opacity on the digital display.
3. Swing open the transceiver and initiate a zero with
the zero switch on the service module to raise the
zero reflector into place. Observe and record the
zero value after 30 seconds. Return the mirror to
normal resting position by returning the zero switch
to operate position.
4. If required, insert a 1/16" Allen wrench into the adjustment set screw located on the top of the zero reflector. Turn
the set screw clock-wise 1/8 turn.
5. Remove the Allen wrench and initiate a zero utilizing the zero switch on the service module and after 15 seconds
observe the reading is moving toward the desired value. (If value is away from desired repeat step 4 turn set screw
C.C.W.)
6. Repeat steps 4 & 5 each time making small 1/8-turn increments until the desired value is reached. Cycle 2-3 times
more waiting 15 to 20 seconds between cycles to assure unit repeats desired value +/- 0.5% Opacity. Swing
transceiver into operate position and secure in place. Record the zero final value.
39
I N S T R U C T I O N M A N U A L R E V 4 . 2
SPAN FILTER VA LU E
1. With the zero switch in zero, place the span switch in span. Span is not adjustable, final value is a function of filter
value, transceiver calibration and OPLR. Record the final value.
2. Return both zero and span switches to operate, normal/test to normal, T2/Opacity to Opacity.
REC ORD THE ZERO/SP A N VALU ES
1. To record the final values you will need to enter the zero and span into the TECH set up page. This completes the
calibration.
OF F S TACK ZERO C ALIBR A TI ON
This procedure may be used if: A clear stack condition is not possible and the zero appears to be incorrect or if the flange to flange
distance on site are different than the original factory set up.
Remove the transceiver and retro reflector from the hinge pins, remove the service module and install the system on OPM Opacity
portable off stack test stands (1A99993H37) and at the correct flange to flange distance plus 11 inches. The additional 11 inches
compensates for air plenum spacing, as the air plenums are not used for the off stack zero calibration.
1. Clean transceiver and retro windows.
2. Connect the control unit with the control to service module test cable kit and apply power to the system.
3. The retro reflector must be level.
4. Follow instruction for "Clear on stack zero and span calibration".
40
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 7 MICRO -TURN AUDIT KIT
USING THE ON LI N E Z ERO R EF L ECTOR (OPTI ON )
The "Micro-turn" 200 on - line test and audit system (p/n 1A99993H24) may be used for:
Opacity audit
Linearity checks and adjustments
System accuracy verification
Service on line or off stack
The "Micro-turn" 200 on - line test and audit system (p/n 1A99993H24) contains a test reflector, three neutral density filters, filter
certification certificates and carrying case.
Filter certification, replacement or additional Neutral Density Filters are available by calling 203-935-0102 ext 10. Ask for Neutral
Density Filter certification information. If not regulated by EPA regulations in your State to a more frequent schedule it is suggested
you re-calibrate Neutral Density Filters used for Opacity Audits at the minimum of 6 months. Filters are tested per USA Code of
Federal Regulations 40CFR60 Appx. B, Performance Specification 1, Section 7.1.3 Attenuation Calibration. Filter certification
Neutral Density Filters for Micro-turn 200 are calibrated on a Perkin-Elmer Lambda Series 6 / PECSS Spectrophotometer per Federal
Environmental Protection Agency specifications. These specifications are contained in the Code of Federal Regulations 40 CFR 60,
Appendix B, Performance Specification 1, Attenuator Calibration. The filters are scanned over the visible region from 380 to 780
nanometers in one nanometer steps and the resulting transmittances of the filter are weighted to the Source C Human Eye
Response by multiplying each value by its associated response factor. The corrected values of transmittance are converted to %
Opacity and the value is recorded on the filter and associated chart.
41
2100*
100
1
11
5.0
2
OP
Op
M
%5.54100*
100
1.23
11
5.0
5.1
I N S T R U C T I O N M A N U A L R E V 4 . 2
FILTER CORRECTION FORMU LA
If you have an OPLR (correlation factor) other than 0.5 your slides will read differently. To calculate what the slide will read with
another OPLR use the formula:
Where:
OP1 = Standard filter Value in %
M2 = OPLR for your instrument
OP2 = Standard Filter value at your OPLR in %
Example:
Standard filter value is 23.1% what will it read at OPLR of 1.5?
42
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 8 PREVENT I V E /CORRECTI VE MAINTENA NCE
PREVEN TIVE/CORR EC T I VE MAI N TEN ANCE SCHEDU LE
Daily:
Check Zero/Span marks are within specification (+/- 2%)
Check for fault conditions
Monthly or as required:
Clean transceiver and retro windows
Check alignment, correct if necessary
Check air filters replace if necessary
Quarterly:
All daily and monthly checks
Perform COM Audit per EPA regulation 40 CFR, 60 App. B, PS-1.
Replace air filters (8 pack 1A99993H09)
Check all air hoses and clamps for tightness and wear, correct as necessary
Check weather cover gaskets for leakage
Check all bolts for tightness
Check all electrical connections are secure
Check air blower for excessive noise
Assure that airflow switch is operating properly
43
I N S T R U C T I O N M A N U A L R E V 4 . 2
Yearly:
Clear stack or off stack zero
All quarterly checks
Remove transceiver and retro, clean air plenum
Replace any worn hoses and gaskets
Clean inner optics if necessary
Check all system operations
General
Corrective and preventive maintenance schedules should be adjusted according to site specific conditions to ensure the maximum
availability of accurate measurement data. Routine checks should be implemented to:
Observe and correct the operation of the air-purge system giving particular attention to keeping the optical path within the
mounting flanges clear of dirt build-up.
Observe and correct the operation of peripheral accessory equipment such as recorders, computers, etc.
Observe and correct the stack zero measurement whenever a clear stack condition exists. Care should be exercised to ensure that
both transmittance and opacity measurements are at their prescribed values.
Verify that instrument operating manuals are available and that maintenance logs are properly maintained and reviewed.
Every 3-5 Years:
It is recommends periodical, depending on the severity of the sensor locations 3-5 years between overhaul of our opacity system to
keep them working at their optimal level. Overhauls become necessary do to the fact that over time dust, out gassing of electronic
parts, removing protective covers, etc., manifest itself as overall optics degradation causing more frequent adjustments and poor
performance of the opacity monitor.
44
I N S T R U C T I O N M A N U A L R E V 4 . 2
Control unit preventive maintenance
Preventive maintenance consists of cleaning the instrument regularly and inspecting it occasionally for broken or damaged parts.
Regular maintenance will improve the reliability of your instrument and prevent breakdowns.
Cleaning - Accumulations of dirt and dust on components act as an insulating blanket preventing efficient heat dissipation. Dust on
circuit boards and wires can cause arcing and short circuits, resulting in damage to components or even instrument failure. Clean
your instrument with clean high-pressure air before this happens!
The control unit chassis provides protection from dust and dirt and should be in place during normal operation of the instrument.
Exterior - Dust the chassis with a soft cloth. Dust the front panel with a soft paintbrush. Dirt clinging to the surface can be removed
with a soft cloth dampened with a mild detergent and water solution. Avoid using abrasive cleaners, as they will scratch the housing
and front panel.
Interior - Dust in the interior of the control unit should be removed before it builds up enough to cause arcing and short circuits
during periods of high humidity. Dust is best removed from the interior by the type of canned air used for computer cleaning. Dirt
clinging to the surfaces can be removed with a soft paintbrush.
Visual Inspection - Inspect the interior occasionally for broken connections, improperly seated semiconductors, damaged or
improperly installed circuit boards, heat damaged components, etc. If heat damaged components are found, care must be taken to
find the cause of the excessive heat and measures must be taken to prevent recurrence of the damage.
Semiconductor Checks - Periodic checks of the semiconductor devices in this instrument are not recommended. The best check of
semiconductor performance is actual operation of the instrument.
Weather cover/blower preventive maintenance
Periodically - Check and inspect all hoses and wire connections inside the weather covers.
Air Filter - Remove and inspect replace the filter cartridge as necessary (8 pack p/n 1A99993H09).
45
Problem
Possible Cause
Remedy
Control unit reads 99%, Alarm icon is on, Fault
message T2 4-20mA FAULT, service module meter in
T2 reads -20 or higher.
Transceiver current loop to the
control unit is open
Service module Operate/test switch must
be in Operate.
Check wiring for open from control unit
AN3 & ACM to terminal 17 & 16 at service
module location.
Alignment is good but control unit reads high opacity
or erratic in normal, zero & span mode, service
module meter in opacity reads high or erratic.
1- Reference voltage TP-2 on
signal processor 1667 is lower
than 9.3V
2- Main lamp out
1- Adjust lamp drive PT-2 on the power
modulator 1668 until Reference voltage TP2 on signal processor 1667 is 10.0 +/-
0.2Volts.
2- Replace main lamp assembly
Control unit reads High, zero/span values are OK
1- Smoke
2- Alignment is out
1- Correct process
2- Adjust alignment until centered on
target.
High dust alarm and /or cal fail cal message
Transceiver window and/or zero
mirror is dirty
Clean window and or zero mirror
Control unit reads High, zero/span values are OK,
alignment is good
Dirt built up in flanges
Swing open transceiver & Retro. Clean
flanges with push rod.
Air purge icon on in the lower right corner of the Main
Display
No air flow
Replace air blowers as necessary
Replace air filters as necessary
Tighten hose clamps as necessary
No stack power fault message
Service module lost power or
failed
Check power, check SM fuse. Replace as
needed
I N S T R U C T I O N M A N U A L R E V 4 . 2
TR O U BLE SHOOTING
46
Problem
Possible Cause
Remedy
Maintenance Mode message
Maintenance switch or
maintenance function is on
1- Control unit zero/span key
was pressed.
2- Service module
zero/operate switch in zero,
span/operate switch in span
3- Service module
test/operate switch in test
Return all to operate
positions.
Control unit blank
Control unit fuse open
Replace and check for shorts
in the power supply or
individual boards.
I N S T R U C T I O N M A N U A L R E V 4 . 2
TR O U BLE SHOOTING -CONTINUED
47
1A99993H03
OPM T Signal processor with detector
board assembly installed.
X
Transceiver
1A99993H04
Power Supply/Modulator Board-PCB
X
Transceiver
1A99993H06
Zero reflector iris assembly with rotary
solenoid, reflector tape and zero arm
for Opacity Transceiver .
X
Transceiver
1A99993H08
Replacement Air flow switch for air
purge blower.
X
Transceiver
Retro reflector
1A99993H09
8 Pack Air filter replacement element
(ID 1.5 OD 4.5 HT 5.875 Black)
X
Transceiver
Retro reflector
1A99993H11
P1 - Service Module output cable
assembly
X
Control Unit
Service Module
1A99993H12
P2 - Transceiver output cable
assembly
X
Transceiver
Service Module
1A99993H13
Service Module Assembly with Digital
display, local zero/span and test
jacks.
X
Service Module
1A99993H30
OPM4000 series control unit to
service module 10' test cable.
X
Control Unit
Service Module
1A99993H35
OPM3000/4000 Series Opacity
Detector Board-PCB
X
Transceiver
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 9 SPARE PAR T S
48
1A99993H36
Retro Assembly Drop on pin type 315Ft.
X
Retro reflector
1A99993H37
Off the Stack Opacity Test Stand for
OPM3000/4000 series.
X
Transceiver
Retro reflector
1A99993H39
Pair of Opacity Air plenum Plant Air
Adaptors, accepts 1/4" or 1/2" NPT
X
Transceiver
Retro reflector
1A99993H40
OPM3000/4000 Series Air Plenum
Assembly (with lift-off hinge), opacity
fits either Transceiver or Retro.
X
Transceiver
Retro reflector
1A99993H41
OPM3000/4000 Series Opacity
Transceiver protective window kit, 3screws, 1-150x50mm lens, 1-O-ring,
1-lens retaining ring.
X
Transceiver
1A99993H42
OPM3000 Control unit s/n 850 up.
Control Unit
1A99993H43
OPM4001 Base Control Unit
Spare/Replacement
X
Control Unit
1A99993H44
OPM4001 Enhanced Control Unit
Spare/Replacement
X
Control Unit
1A99993H45
OPM SD Standard Backup Card
(2GB)
X
Control Unit
OPM4000 Series Service Module
Zero-Span controller main PC board.
X
Control Unit
I N S T R U C T I O N M A N U A L R E V 4 . 2
49
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ION 10 DRAWINGS
It is recommended to print drawings with the highest print quality.
50
I N S T R U C T I O N M A N U A L R E V 4 . 2
OP M6 1 27 1OF3 – C ONTROL UNIT TO SEN S OR W IRIN G /DUA L B LOW ER
51
I N S T R U C T I O N M A N U A L R E V 4 . 2
OP M6 1 27 2OF3 – C ONTROL UNIT TO SEN S OR W IRING / SINGLE BLOWER
52
I N S T R U C T I O N M A N U A L R E V 4 . 2
OP M6 1 27 3OF3 – C ONTROL UNIT TO SEN S OR W IRING / NO BLO W ER
53
I N S T R U C T I O N M A N U A L R E V 4 . 2
RS485 : PIN OUT
Use RS485 to create a multi-drop network containing up to 32 devices.
Note: port #1is set to RS485
Note that the ports are not isolated. If
controller is used with a non-isolated
external device, avoid potential voltage
that exceeds +/- 10V. To avoid damaging
the system, all non-isolating device ports
should relate to the same ground signal.
Use shielded, twisted pair cables.
Minimize the stub (drop) length leading
from each device to the bus.
Ideally, the main cable should be run in and out of the network device.
Do not cross positive (A) and negative (B) signals. Positive terminals must be wired to positive and negative terminals to
negative.
54
High mg
Alarm 011:
0=open, 1=
closed
High Op AL
012: 0=open,
1= closed
mg/Op Alarm
silence O13:
0= open, 1=
closed
E.W. Op AL
O15: 0=
open, 1=
closed
E.W. mg
Alarm O16:
0= open, 1=
closed
Auto alarm reset without pushing rest button.
Start 0%, use test value above High set points.
0 0 0 0 0
> Hi Mg 150mg set point after delay satisfied (AL)
1 1 1 1 1
> Hi Op 20% set point after delay satisfied (AL)
1 1 1 1 1
Return to 0%
0 0 0 0 0
Auto alarm reset pushing rest button before returning to zero.
Start 0%, use test value above High set points.
0 0 0 0 0
> set point after delays satisfied (AL)
1 1 1 1 1
> set point EW, Reset button pushed
1 1 1 1 1
> set point Process Alarm, Reset button pushed
1 1 0 1 1
Return to 0%
0 0 0 0 0
Manual alarm reset after returning to zero.
Start 0%, use test value above High set points.
0 0 0 0 0
> set point after delays satisfied (AL)
1 1 1 1 1
Return to 0%
1 1 1 1 1
Process Alarm reset button pushed
0 0 0 1 1
EW reset button pushed
0 0 0 0 0
Manual alarm reset before, than after returning to zero.
Start 0%, use test value above High set points.
0 0 0 0 0
> set point after delay satisfied (AL)
1 1 1 1 1
Process Alarm reset button pushed
1 1 0 1 1
EW reset button pushed
1 1 0 1 1
Return to 0%
1 1 0 1 1
Process Alarm reset button pushed
0 0 0 1 1
EW reset button pushed
0 0 0 0 0
I N S T R U C T I O N M A N U A L R E V 4 . 2
SECT ON 11 ALARM MA T RIX
55
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