Rosemount OPM 4000 Opacity / Dust Density Monitor Installation and Operational Manual- Rev 2.1 Manuals & Guides

Instruction Manual 2.1

OPM4001 Opacity/Dust Density Monitor
Installation and Operation Manual

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Instruction Manual 2.1

Table of Content

Contents

TECHNICAL SUPPORT HOTLINE ...........................................................................................................4

SECTION 1 SYSTEM DESCRIPTION .......................................................................................................6

TRANSMISSOMETER /RETRO REFLECTOR ............................................................................................................ 6

REMOTE CONTROL UNIT (RCU) ...................................................................................................................... 8

Optional Air Purge Weather Cover System ........................................................................................... 8

Alignment system .................................................................................................................................. 8

Cabling ................................................................................................................................................... 8

OPM4001 Specifications: ....................................................................................................................... 9

SECTION 2 INSTALLATION CONSIDERATIONS .................................................................................... 11

REGULATORY/PROCESS CONSIDERATIONS ....................................................................................................... 11

STACK EXIT CORRELATION COMPUTATIONS ..................................................................................................... 12

INSTALLATION – MECHANICAL ....................................................................................................................... 14

Installation procedure - stack flanges .................................................................................................. 14

FLANGE TO STACK INSTALLATION .................................................................................................................... 16

MOUNTING THE AIR PLENUM AND WEATHER COVERS ........................................................................................ 18

Transceiver and retro reflector assembly ............................................................................................ 19

SECTION 3 REMOTE CONTROL UNIT (RCU) OPERATION PAGE DESCRIPTION ....................................... 20

RCU BUTTONS ............................................................................................................................................ 20

About page .......................................................................................................................................... 20

START UP VERIFYING INSTRUMENT OPERATION AND CONFIGURATION .................................................................. 22

Scrolling multiple main display pages .................................................................................................. 25

Password protected parameters ......................................................................................................... 26

SECTION 4 MODBUS ......................................................................................................................... 28

Modbus Setup ...................................................................................................................................... 28

Modbus Write ...................................................................................................................................... 28

Modbus Read ....................................................................................................................................... 29

RS/485 COMMUNICATIONS AND CONNECTION ............................................................................................... 30

RS485: Pin out ...................................................................................................................................... 30

SECTION 5 OUTPUT CONNECTIONS ................................................................................................... 31

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Instruction Manual 2.1

Channel #1 and 2, 0-100% Opacity 4-20mA outputs to recording devices ......................................... 31

ALARM OUTPUT CONNECTIONS ..................................................................................................................... 32

Group 1: ............................................................................................................................................... 32

Group 2: ............................................................................................................................................... 32

ANALOG OUTPUTS 4-20MA .......................................................................................................................... 33

Other output connections possible ..................................................................................................... 34

SECTION 6 CLEAR PATH ADJUSTMENTS ............................................................................................. 35

SERVICE MODULE ........................................................................................................................................ 35

CLEAR ON STACK ZERO AND SPAN CALIBRATION ................................................................................................ 36

ZERO REFLECTOR ADJUSTMENT ...................................................................................................................... 38

Off stack zero calibration ..................................................................................................................... 39

SECTION 7 FILTER CORRECTION FORMULA ........................................................................................ 40

Filter certification ................................................................................................................................ 41

SECTION 8 PREVENTIVE/CORRECTIVE MAINTENANCE ....................................................................... 42

Preventive/corrective maintenance schedule ..................................................................................... 42

Trouble Shooting ................................................................................................................................. 45

Trouble shooting -continued ............................................................................................................... 46

SECTION 9 SPARE PARTS .................................................................................................................. 47

SECTION 10 DRAWINGS .................................................................................................................... 49

OPM4001 CONTROL UNIT DIMENSIONS ......................................................................................................... 49

OPM6142 1OF3 - WIRING .......................................................................................................................... 51

OPM6142 2OF3 - WIRING .......................................................................................................................... 52

OPM6142 3OF3 - WIRING .......................................................................................................................... 53

RS485: PIN OUT ......................................................................................................................................... 54

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Instruction Manual 2.1

Technical Support Hotline

For assistance with problems, please call the Customer Support Center (CSC).

Phone: [phone]

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: [phone]-RMST (1-800-654-7768)

Emerson Process Management may also be reached via the Internet through e-mail and World Wide

e-mail: [e-mail]

World Wide Web: www.raihome.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 is 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.

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Instruction Manual 2.1

 You may cause an electric shock, fire or damage the equipment if you ignore any of these safety

precautions.

Manual Prepared by James F. Cognetta

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Instruction Manual 2.1

Section 1 System description

Transmissometer /retro reflector

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 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.

2

The (T
control unit the signal is processed to read 0-100% Opacity, provide alarms and outputs.

) signal is converted to a current format and sent to the control unit for processing. At the

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Instruction Manual 2.1

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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Instruction Manual 2.1

Remote Control Unit (RCU)

The RCU provides instrument control functions, opacity readings,
alarms, analog outputs, communications, system information and
more. The RCU can be DIN rail mounted or panel mounted
(3.7x3.7” – 93x93mm) in a control room environment and 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 +

o

122

F). The control unit provides instrument control functions,
opacity readings, alarm and fault indicators, analog outputs, and
diagnostics with contact closures.

Optional Air Purge Weather Cover System

The transceiver and reflector may be mounted in weather covers. The weather
covers are fairly compact to allow movement around them even on a three­foot 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 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 3­point 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 cable separation distance approximately 1000FT. More pairs or larger than
20 AWG is acceptable.

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Instruction Manual 2.1

Remote Control unit:

Enclosure

Panel mounted IP65/NEMA4X Dimensions 96x96x64 mm
(3.8”x3.8’x2.5”).

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

Two 12-bit Analog outputs 4-20mA, Field selectable range -

5.0 to 100%.

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

OPM4001 Specifications:

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Instruction Manual 2.1

Transceiver/ Reflector:

Enclosure/Power Requirements

NEMA 4X watertight enclosure. 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 LSEM (Light Source Electronic Modulation).

Ambient Light Immunity

Solid state LSEM (Light Source Electronic Modulation)
Reflector

Type 1 (plastic) reflector assembly

Alignment Verification

Built-in through-the-lens system standard

LSEM Aging Compensation

Automatic

LSEM 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

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

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Instruction Manual 2.1

Section 2 Installation Considerations

Regulatory/Process Considerations

The EPA has established the following guidelines for choosing an opacity/dust density monitor
installation site:

1) Locate the transmitter across a section of a duct or stack that will provide a particulate

matter flow through the path of the transmitter beam representative of the duct or stack
flow.

2) Ensure the transmitter location is down-stream from all particulate control equipment.

3) Locate the transmitter as far from bends and obstructions as practical.

4) If a transmitter is to be located less than 4 duct diameters downstream from a bend, install

the transmitter in the plane defined by the bend, as shown in the figure below.

5) Ideally, locate the transmitter eight to ten stack diameters upstream from the stack exit

and three to five diameters downstream from any bends, junctions, or other constrictions
in the stack or duct.

For best results, mount the transceiver and retro reflector modules so the light beam is exactly
perpendicular to the stack or duct and the beam goes through the center. Do not install the transmitter
downstream of a wet scrubber. The water droplets introduced to the gas stream by such equipment will
interfere with the opacity readings. For an accurate measurement under these conditions, choose a
location upstream from a wet scrubber or a location downstream from the scrubber where the water
droplets are vaporized by the reheating of the gas. 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.). Check that the calculated and the O.P.L.R.
found in the Factory OPLR Check step found further in this section
are within +/- 2%.

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Instruction Manual 2.1

Lt

Lx

OPLR*2

50.0

120*2

120

OPLR

Stack Exit Correlation Computations

NOTE: The stack exit correlation is especially important to verify. If possible, all dimensions should be
verified by actual measurements. Using the instructions below verify that the values are correct as
displayed in the About page.
Lx/Lt is the ratio of the inside diameter at the top of the stack to the inside diameter of the stack where

the instrument is located. If the ratio is greater than 1.0, the exit opacity will be greater than the opacity
at the instrument location. The OPM4001 uses this correction factor to calculate the stack exit opacity. It
is not practical to have an Lx/Lt factor much greater than 2.0 because the error of the instrument
increases as Lx/Lt becomes greater.

Lx = inside stack diameter at stack exit.

Lt = inside stack diameter at the transmitter location.

Lf = flange to flange distance between the transceiver and retro reflector unit.

1) Measure and record Lx and Lt and compute the Optical Path Length Ratio (OPLR).

2) Check that the calculated value and the

OPLR found in the 2nd About page are within
±2%.

3) Example: A stack with a 120 in. (3048 mm)

stack exit ID and a 120 in. (3048 m) path
length.

4) Enter the exit

diameter (Lx) and measured diameter (Lt) in
the control unit. Refer to Section 4:
Operation, for info on using the control unit.

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Instruction Manual 2.1

Choose an installation site; the primary considerations for choosing a site for the OPM4001 are
accessibility, ambient environmental conditions, and locating the unit to obtain a representative sample
of the process. Review the excerpt from the Federal Register in appendix for suggestions before
selecting an installation site. The following general guidelines should also be considered.

Sensors height from Platforms, walk way/ decks, etc, A platform or walkway must be available for access
to the weather covers. The optimum condition would have the mounting flanges and weather covers
approximately 5 feet up from the floor. Railings and other obstructions should allow the weather cover
to swing clear as shown in the installation drawings.

Locate the stack-mounted units in an area with ambient temperatures between -4 o to +130o F.
(Consult the factory for other temperature ranges.) Areas that are clean and dry are desirable. Avoid
areas with condensation.

Maintenance intervals are directly related to the installation environment. Intervals can vary from 2 to 3
months in fairly clean
environments, to twice a
month in dirty environments.
Lens cleaning is a function of
the ambient conditions and
cleanliness of the purge air.

Locate the instrument to
avoid excessive vibration or
shock.

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.

Stack exit, Locate the transceiver more than two stack diameters down from the stack exit is
recommended.

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Instruction Manual 2.1

Installation – Mechanical

A review of the drawings and procedures provided will help to produce an error free installation.
However, there are important additional points that must be observed. The beam of the instrument

must be kept in the horizontal plane; the transceiver cannot be rotated more than +/- 10 o from vertical.
The weather covers must be
installed vertically plumb.

Installation and wiring diagrams are
found at the end of this manual.
Please review all drawings prior to
starting installation or wiring. If you
have any questions please contact
our Customer Support Center (CSC)
Phone: [phone] or 1-440­914-1261

E-mail: [e-mail]

Installation procedure - stack
flanges

For an opacity monitor, the
customer is required to supply and
install two 3" I.P.S. flanges at eye
level directly across from each
other. The flange faces, mounted
on pipe stubs, should be
approximately 6" to 8" from the
stack or insulation. On completion
of the installation, the flanges must
be aligned so that the total
deviation of the light source flange
relative to a common centerline,

does not exceed +1o and the retro reflector flange does not exceed +3o .

Flanges should be mounted approximately 5 feet up from the deck of platforms, roof or walk way.

At installations where conditions permit, this may be accomplished by using a piece of 2 1/2" pipe
suspended across the stack protruding far enough to allow slipping the 3" flange pipe assemblies over
each end and welding in place as shown on the following page.

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Instruction Manual 2.1

Any deviation up to the previously specified limits can be adjusted out during the installation and
alignment of the light source and retro reflector with the system's alignment adjustments.

Where installations do not permit the use of the aforementioned method, the following procedure will
accomplish the same results. (See drawing EMS1002. An alignment tool can be purchased from the
factory to insure accurate alignment.

Accurately locate
one 3 1/2"
diameter hole
(large enough to
accept the 3" pipe)
and the other hole
approximately 1/2"
diameter, directly
across from each
other. Attach the
alignment tool to
the flange/pipe
assembly and
insert the pipe into
the 3 1/2" hole in
the stack wall.
Align the assembly
with the 1/2"
diameter hole on
the opposite side
by viewing through
the alignment tool
and weld the pipe
in place. Care must
be exercised when
welding to
maintain
alignment.

The 1/2" diameter
hole should now be
enlarged
approximately 3 1/2" to accept the other flange/pipe assembly. Proceed in the same manner, installing
the assembly with the alignment tool attached, and weld in place maintaining concentric alignment with
the 3" pipe previously installed on the opposite wall.

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Instruction Manual 2.1

Flange to stack installation

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Instruction Manual 2.1

Air purge/Weather cover mechanical Installation

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Instruction Manual 2.1

Mounting the air plenum and weather covers

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 EMS - 1001 and EMS - 1002.
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, un­clip 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.

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Instruction Manual 2.1

Transceiver and retro reflector assembly

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!

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Instruction Manual 2.1

When power is first applied press ESC to display the Main page.

The left, right, up, down arrows are used to move display arrows or move
to other pages.

The ESC button is used to move back from the page you are on to the

previous page.

The enter or return button is used when entering variable. Press it
and the variable will change from steady to blinking, enter the new value
and follow screen tip at the bottom to complete the operation.

The info button is used for setting the PLC functions. This is not used
during normal operation. When required the use of the functions will be
explained in this manual.

The key pad is used to enter values.

The +/- is used when (–) sign for values are required.

These buttons are not used on this model.

Section 3 Remote Control Unit (RCU) operation Page Description

RCU buttons

About page

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Instruction Manual 2.1

When power is first applied press ESC to display the screen
for the operator to select the function of interest by pushing
the Up or the Down Arrow to select the function desired,

press the return/enter button .

By pushing UP or the DOWN arrow you can select the OPM4001

Display, Setup or About pages. Use the return/enter button to enter the
page (screen) you desire.

To get to the About page scroll down to
About and press the right arrow button to
enter the 1st page of the about page. This
will display the Model & s/n, Date of
manufacture and Flange to Flange.

About page 2 displays Modbus network,
Stack exit I.D., Path length I.D. and OPLR
(Optical Path Length Ratio).

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Instruction Manual 2.1

Start up Verifying instrument operation and configuration

Zero/Span Check

For assistance with problems, please call the Customer Support Center (CSC).

Phone: [phone]

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: [phone]-RMST (1-800-654-7768)

Worcester Polytechnic Institute may also be reached via the Internet through e-mail and World Wide
Web:

e-mail: [e-mail]

World Wide Web: www.raihome.com

World Wide Web: www.raihome.com

Alignment procedure must be completed as outlined in Section 2.

Power applied to both the control unit and the sensors for a minimum of 30 Minutes before any
adjustments are attempted.

The zero calibration has been set at the factory by placing the instrument on an optical bench using the
flange-to-flange dimensions specified by the customer and recorded in the customers final test report.
This zero value is critical as it can offset smoke measurement plus or minus if not correctly set. The
measurement reflector contains an aperture that is chosen during the factory calibration and is fixed.
The Transceiver is aligned with the beam centered on the retro reflector and the electronics is adjusted
to produce a zero opacity value.

The calibration zero reflector is adjusted to provide a low value typically 1-2% and the span filter upscale
value is recorded and entered in the set up page under “Fault setup" When the system enters a manual
or auto cal check cycle the current zero and span values are checked against the stored values. If either
the zero or span current value exceeds the stored value by +/- 2% opacity the fault system will energize.

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Instruction Manual 2.1

Initiate a Z/S check by pressing the F1 button. The next screen will

ask you for a selection; press Enter to choose “Yes”. The screen will

return to the Display and the Right column will show In Cal icon.
When the zero check “Instant value” stabilizes (@15 seconds) record
the zero value. The Zero check will remain for 3 minutes, next will be
Span and will last for another 3 minutes. When Span is stabilized
record the span upscale value. The system will automatically return
to monitoring the process at the 6 minute point from cal start. You
will know this because the In Cal icon will turn off.

Check to see if the controller has the same values by pressing ESC

and scroll down to the Setup and press return/enter button
you will be at the password page. Enter 1234 from key pad and press
the return/enter button.

Scroll to Cal Z/S Value setup and press the return/enter button .
The true span check will be blinking. If zero and span values are the
same as you recorded +/- 0.5% opacity do nothing just press the ESC
button. Should the displayed values be greater than +/- 1.0% but less
than 3% from your recorded values enter the recorded values. Press

the right arrow to highlight the value to change. Press the
return/enter button and use the key pad to enter your value. Press
the +/- dot button above the return/enter button for decimal point.
When correction is made press the return/enter button to save (it
will stop blinking and move to the next value).

The Fault squelch timer should be left at 1 Min.

The fault timer is that time from fault detection to initiation of the
fault alarm and should be not less than 10 seconds.

The ( –ve) negative opacity fault YES= on, NO= Off.

When you are finished press the ESC to exit.

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Instruction Manual 2.1

NOTE: If the Zero or Span value stored is +/- 3% Opacity from your
recorded value contact our service department because it may
indicate other adjustments are required.

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Instruction Manual 2.1

Pressing ESC will get you back to the selection page, scroll to OPM4001

Display and press return/enter button the process opacity display page
will be displayed:

Upper line; Next cal in HH:MM:SS

Middle line; Instant opacity %

Bottom line; 6 Minute average opacity %

Pressing the up or down arrow you can scroll to the 3 display pages that is
best for your application.

Page 1 is a split screen with instant and average opacity. NOTE: If input goes

negative a 4th screen will appear, when signal goes positive it will return to
page 1 the default page.

Page 2 is average opacity only.

Page 3 is Instant opacity only.

Scrolling multiple main display pages

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Instruction Manual 2.1

Password 1234 - From any screen press ESC
until the Main, setup and about screen is
visible. Scroll to Setup and press the
return/enter button. The password is 1234.

Alarm set point - return/enter button and
set the alarm set point from 0-99% and
the alarm delay – In seconds. Press enter
to set, ESC to exit.

Calibration Cycle setup – Press
return/enter button and set the
frequency you want the cal cycle to
initiate. EPA regulations call for 24hr.
The OPM4001 will initiate the cal cycle if

Cal trigger is “Internal”. To use an

external command scroll down to cal
trigger and choose external by pressing
key pad #2 then press return/enter
button to set. Input momentary ground
to I3.

Note: No input to I3 and External selected the system will not go into cal
cycle, however you can still use the F1 button to force an manual cal cycle.

Password protected parameters

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Instruction Manual 2.1

Alarm Auto/Manual setup – Press return/enter
button to enter. Choose between 1-auto or 2­manual.

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 de­energised.

Output type setup – Press return/enter
button to enter. “Output type” refers to
the 4-20mA outputs.

Ins – instant opacity, z/s outputted during
cal cycle.

Avg – 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.

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%

Page | 27

Instruction Manual 2.1

MODBUS I.D. – 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.

Write:

Remote Cal. Initiate

MB 51

Initiate cal =1

In maintenance

MB 49

In Maint. =0, Not In Maint.
=1

Power status

MB 50

Lost power to SM (service
module) =0, Power OK =1

T2 Signal

MB 34

Signal OK =0, Lost signal =1

-ve opacity

MB 37

Positive opacity =0,
Negative Opacity =1

Zero Cal Fail

MB 38

Fail =1, Not fail =0

Span Cal Fail

MB 39

Fail =1, Not fail =0

Section 4 Modbus

Modbus Setup

Modbus Write

Page | 28

Instruction Manual 2.1

MB = Modbus Poll Read Discrete inputs (100001….20000)

MI = Modbus Poll Read Holding (40000…50000)

Read:

0% to 100% (x.x) instantaneous opacity

MI 35

Read

0% to 100% (x.x) average opacity

MI 98

Read

Relay 05 (Zero DAS)

MB 43

Zero, not cal = 0, in cal =1

Relay 06 (Span DAS)

MB 44

Span, not cal = 0, in cal =1

Relay 07 (No Air flow)

MB 45

OK =0, Not OK =1

Relay 03 (High alarm Audible)

MB 46

No alarm =0. Alarm =1

Relay 04 (Fault)

MB 47

No fault =0. Fault =1

Relay 02 (High alarm)

MB 48

No alarm =0. Alarm =1

Alarm Set point

MI 22

Read

Alarm delay

MI 24

Read

Common fault individual blocks:

Modbus Read

Page | 29

Instruction Manual 2.1

RS/485 Communications and connection

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.

If not specified in the original order default is as follows. NOTE: The following communication
perimeters 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.

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.

Page | 30

Instruction Manual 2.1

Section 5 Output Connections

Channel #1 and 2, 0-100% Opacity 4-20mA outputs to recording devices

(Maximum 500 ohm device load) Connect the (-) minus wire from your device to the bottom connector
terminal 0V and the (+) plus wire from your device to the terminal AO for channel 1 and AI for channel 2.

Page | 31

Instruction Manual 2.1

Alarm output Connections

Alarm outputs are SPST relays. There are 2 groups each group has its own common, See drawing
OPM6142 for connection details. Relays are rated at: 30Vdc, 3Amp max per relay and 8Amp max per
common. If you need to switch high voltage AC contact the factory for assistance.

Group 1:

Reference drawing OPM6142

00 & 01 - DO NOT USE dedicated for z/s command lines to service module.

02 - High opacity alarm relay

02 Set point and delay are chosen in the setup page. Choose Auto or manual mode in the setup page.
For 02 to be utilized as a boiler shut down you must select “Manual” in the alarm set up page.

03 - High opacity Audible alarm relay

03 may be used for audible alarm and can be reset (acknowledged) even if the opacity is still above the
set point.

Group 2:

Reference drawing OPM6142

04 - Common FAULT RELAY

Faults are; Maintenance, Power status, T2 Signal, -ev
(Negative opacity), Zero cal and Span cal.

Note: the –ev (Negative opacity) can be turned on or
off by the user see page 25 for instructions.

05 - ZERO to DAS relay

Cal in progress or zero is by dry contacts on terminal
05 group 2 common. This contact remains closed
until cal is completed, i.e. both zero & span.

06 - SPAN to DAS relay

Cal span is by dry contact on Terminal 06 & group 2 common. This contact remains closed during Cal
span.

07 - Air purge alarm relay

Page | 32

Instruction Manual 2.1

Analog outputs 4-20ma

The OPM4001 comes with two 4-20mA output channels. The ranges are set during final test 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: 0V & A0 supplies the opacity signal to the service module 14 & 13 (on TB1, OPM6142) for
display at the service module.

Channel 2: 0V & A1 can be used for DAS, recorder etc.

Page | 33

Instruction Manual 2.1

Other output connections possible

To utilize an external device (max 250 ohm) in Ch1 current loop:

To utilize an external device in Ch2 current loop (max 500 ohms total):

To check devices such as recorders or DAS are responding correctly use the following procedure; On the
control unit front panel press the F1 Push button to put the system in a maintenance zero and span
cycle. Both outputs will correspond to the opacity display value.

Page | 34

Instruction Manual 2.1

Section 6 Clear Path Adjustments

Service module

Page | 35

Instruction Manual 2.1

Clear on stack zero and span calibration

The instrument has been calibrated at the factory to specifications received with the order and if the
actual dimensions of the flange to flange are exactly as received the calibration adjustments required
will be minimal or none at all. The following adjustments are for the first time the instrument is
installed. To calibrate or adjust the OPM4001 use the following steps.

NOTE: Calibration must be performed with the process shut down to produce a clear stack condition. If
a clear conditions is not possible go to “Off stack zero calibration” procedure later in this manual.

Before proceeding clean both transceiver and retro reflector lens.

Remove the transceiver cover (Always disconnect power when removing or replacing the transceiver
cover) by removing the screw below the target viewing window and pulling the cover straight back until
it clears the Optical plate.

To complete this procedure the following items are required: Micro-turn 200 on-line test kit (p/n
6A00188G07) a manual for the audit device is included with the device.

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 (Figure 2) the normal/test switch must be in the “Normal” position and

the Opacity/ T2 is in “Opacity” position. NOTE: All adjustments are on the PCB 222-
1667 (p/n 1A99993H03 for replacement).

5. Adjust the 20 turn Zero potentiometer on board

222-1667 marked "PT -1", CW until you increase to
about 20% opacity, then slowly turn the PT-1 CCW
until you have Zero % opacity, 0-1% opacity.

6. 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.

7. 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 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.

8. Remove the filter and adjust the Zero potentiometer PT-1 for 0-1%.

Page | 36

Instruction Manual 2.1

9. Insert the High filter again adjust PT-3 for its value, repeat steps until the values come within

0.5 % Opacity.

10. 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.

Page | 37

Instruction Manual 2.1

Zero reflector adjustment

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" Alan 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 Alan 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.

Span filter value

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.

Record the zero/span values

1. To record the final values you will need to enter the zero and span into the set up page

under “Cal Z/S Value setup “. This completes the calibration.

Page | 38

Instruction Manual 2.1

Off stack zero calibration

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.

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 portable off stack test stands (p/n 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 cables that came with the Off Stack 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".

Page | 39

Instruction Manual 2.1

2100*

100

1

11

5.0

2

OP

Op

M























































%5.54100*

100

1.23

11

5.0

5.1







































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

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

Section 7 Filter correction formula

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?

Filter re-calibration is available from EMS and if not regulated by EPA regulations in your State to a more
frequent schedule we suggest you re-calibrate at the minimum of once a year. If you have filters from
other manufacturers we can also calibrate them as well (call for pricing). Filters are tested per USA Code
of Federal Regulations 40CFR60 Appx. B, Performance Specification 1, Section 7.1.3 Attenuation
Calibration.

Page | 40

Instruction Manual 2.1

Filter certification

QA/QC testing of the filters at an interval of not more than 6 months is recommended. Filter
certification, replacement or additional Neutral Density .

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.

Page | 41

Instruction Manual 2.1

Section 8 Preventive/Corrective Maintenance

Preventive/corrective maintenance schedule

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

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

Page | 42

Instruction Manual 2.1

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:

EMS 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.

Page | 43

Instruction Manual 2.1

For assistance with problems, please call the Customer Support Center (CSC).

Phone: [phone]

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: [phone]-RMST (1-800-654-7768)

Worcester Polytechnic Institute may also be reached via the Internet through e-mail and World Wide
Web:

e-mail: [e-mail]

World Wide Web: www.raihome.com

World Wide Web: www.raihome.com

Warnings and Safety Guidelines for user safety and equipment protection

Page | 44

Instruction Manual 2.1

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

Operate/test switch must be in
Operate.

Check wiring for open from control
unit I6 & 0V 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 TP-2 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

Trouble Shooting

Page | 45

Instruction Manual 2.1

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.

Trouble shooting -continued

Page | 46

Instruction Manual 2.1

1A99993H03

OPM T Signal processor with
detector board assembly installed.

X

Transceiver
1A99993H04

Power Supply/Modulator Board­PCB

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

Section 9 Spare parts

Page | 47

Instruction Manual 2.1

1A99993H36

Retro Assembly Drop on pin type
3-15Ft.

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,
3-screws, 1-150x50mm lens, 1-O­ring, 1-lens retaining ring.

X

Transceiver

1A99993H43

OPM4001 Base 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

Page | 48

Instruction Manual 2.1

Section 10 Drawings

It is recommended to print drawings with the highest print quality.

OPM4001 control unit dimensions

Page | 49

Instruction Manual 2.1

Page | 50

OPM6142 1of3 - wiring

Instruction Manual 2.1

OPM6142 2of3 - wiring

Page | 52

Instruction Manual 2.1

OPM6142 3of3 - wiring

Page | 53

Instruction Manual 2.1

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.

Page | 54