Emerson OPM4001 Installation And Operation Manual
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Emerson OPM4001 Installation And Operation Manual

Emerson OPM4001 Installation And Operation Manual

Opacity/dust density enhanced controller
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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
OPM4001 Opacity/Dust Density Enhanced
Controller Installation and Operation
Manual

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  • Page 1 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...

  • Page 2: Table Of Contents

    I N S T R U C T I O N M A N U A L R E V 4 . 2 CONTENTS TECHNICAL SUPPORT HOTLINE ............................4 SECTION 1 SYSTEM DESCRIPTION ............................5 Transmissometer /retro reflector ..........................5 RCU.....................................
  • Page 3 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 ..............................
  • Page 4 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 1 3 – CONTROL UNIT TO SENSOR ...................

  • Page 5: Technical Support Hotline

    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...

  • Page 6: 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.
  • Page 7 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.

  • Page 8: Rcu

    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.

  • Page 9: System Specifications

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SYSTEM SPECIFICATIONS 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...
  • Page 10 I N S T R U C T I O N M A N U A L R E V 4 . 2 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...

  • Page 11: Section 2 Installation Considerations

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 2 INSTALLATION CONSIDERATIONS BEFORE 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.

  • Page 12: Mounting The Air Plenum And Weather Covers

    I N S T R U C T I O N M A N U A L R E V 4 . 2 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 OPM6130 and 6131.

  • Page 13: Transceiver And Retro Reflector Assembly

    I N S T R U C T I O N M A N U A L R E V 4 . 2 TRANSCEIVER AND RETRO REFLECTOR ASSEMBLY 6) Attach the Transceiver and Retro reflector to the air plenum assembly by placing them on the hinge pins.

  • Page 14: Beam Alignment Procedure

    I N S T R U C T I O N M A N U A L R E V 4 . 2 BEAM ALIGNMENT PROCE DURE 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.

  • Page 15: Air Flow Switch

    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.

  • Page 16: Section 3 Before Start Up

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 3 BEFORE START UP You must complete the following before start up is attempted.  Check that all parts have the identical serial numbers. ...

  • Page 17: Section 4 Control Unit Page Description

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 4 CONTROL UNIT PAGE DESCRIPTION CONTROL UNIT SCREENS GENERAL PAGE LAYOUT...

  • Page 18: Control Unit Glossary Of Terms

    I N S T R U C T I O N M A N U A L R E V 4 . 2 CONTROL UNIT GLOSSARY OF TERMS OUTPUT TYPE SETUP – “Output type” refers to the 4-20mA outputs.  Instant opacity, z/s outputted during cal cycle.

  • Page 19: Company Information Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 COMPANY INFORMATION PAGE When power is first applied the company info page is displayed. Wait a few seconds and the Home page will appear.

  • Page 20: Calibration Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 CALIBRATION PAGE 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).

  • Page 21: Settings Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SETTINGS PAGE 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.

  • Page 22: Operator Setup

    I N S T R U C T I O N M A N U A L R E V 4 . 2 OPERATOR SETUP 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.
  • Page 23 I N S T R U C T I O N M A N U A L R E V 4 . 2 All raised buttons can be touched and values changed. Instructions are on the bottom of the screen when required.
  • Page 24 I N S T R U C T I O N M A N U A L R E V 4 . 2 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.

  • Page 25: Set Local Time And Date

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SET LOCAL TIME AND DATE To set to local time touch and hold any part of the Yellow back ground until Info Mode appears. 1.
  • Page 26 I N S T R U C T I O N M A N U A L R E V 4 . 2 All raised buttons can be touched and values changed. All flat buttons are read only. All raised buttons can be touched and values changed.

  • Page 27: Change Passwords

    I N S T R U C T I O N M A N U A L R E V 4 . 2 CHANGE PASSWORDS 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).

  • Page 28: Diagnostics Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 DIAGNOSTICS PAGE 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.

  • Page 29: Alarm Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 ALARM PAGE 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.

  • Page 30: Display Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 DISPLAY PAGE Touch the buttons to go to the display of interest. Pages are: 1. Instant Opacity 2.

  • Page 31: About Page

    I N S T R U C T I O N M A N U A L R E V 4 . 2 ABOUT PAGE About page displays the basic setup information.

  • Page 32: Section 5 Modbus And Analog Outputs

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 5 MODBUS AND ANALOG OUTPUTS MODBUS ADDRESS INFORMATION MB = Modbus Poll Read Discrete inputs (10001….20000) MI = Modbus Poll Read Holding (4001…50000) Read: 0% to 99.9% instantaneous opacity...
  • Page 33 I N S T R U C T I O N M A N U A L R E V 4 . 2 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...

  • Page 34: Rs/485 Communications And Connection

    I N S T R U C T I O N M A N U A L R E V 4 . 2 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.

  • Page 35: Alarm Relay Descriptions

    Alarm outputs are SPST relays. Relays are rated at: 30Vdc, 3Amp max per relay and 8Amp max per common. Common for Relays 08- 16 should not be connected to other commons on the controller. OPM4001 ENHANCED Relays Group 1 Relays...

  • Page 36: Analog Output Connections

    I N S T R U C T I O N M A N U A L R E V 4 . 2 ANALOG OUTPUT CONNEC TIONS...

  • Page 37: Output Channels #1, 2, 3 And 4

    4-20MA 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.

  • Page 38: Service Module

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SERVICE 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.

  • Page 39: Section 6 Clear Path Adjustments

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 6 CLEAR PATH ADJUSTMENTS CLEAR ON STACK ZERO AND SPAN CALIBRATION A clear stack condition must exist to perform this calibration. Power must have been on for no less than 30 minutes.

  • Page 40: Zero Reflector Adjustment

    I N S T R U C T I O N M A N U A L R E V 4 . 2 ZERO REFLECTOR ADJUSTMENT After a clear or off stack zero has been performed the zero reflector needs to be adjusted. 1.

  • Page 41: Span Filter Value

    I N S T R U C T I O N M A N U A L R E V 4 . 2 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.

  • Page 42: Section 7 Micro-Turn Audit Kit

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 7 MICRO -TURN AUDIT KIT USING THE ON LINE ZERO REFLECTOR (OPTION) The "Micro-turn" 200 on - line test and audit system (p/n 1A99993H24) may be used for: ...

  • Page 43: Filter Correction Formula

    I N S T R U C T I O N M A N U A L R E V 4 . 2 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: ...

  • Page 44: Section 8 Preventive/Corrective Maintenance

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 8 PREVENTIVE/CORRECTIVE MAINTENANCE PREVENTIVE/CORRECTIVE MAINTENANCE SCHEDU LE Daily: Check Zero/Span marks are within specification (+/- 2%) Check for fault conditions Monthly or as required: Clean transceiver and retro windows...
  • Page 45 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...
  • Page 46 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.

  • Page 47: Trouble Shooting

    I N S T R U C T I O N M A N U A L R E V 4 . 2 TROUBLE SHOOTING Problem Possible Cause Remedy Control unit reads 99%, Alarm icon is on, Fault Transceiver current loop to the Service module Operate/test switch must message T2 4-20mA FAULT, service module meter in control unit is open...

  • Page 48: Trouble Shooting -Continued

    I N S T R U C T I O N M A N U A L R E V 4 . 2 TROUBLE SHOOTING -CONTINUED Problem Possible Cause Remedy Maintenance Mode message Maintenance switch or Return operate maintenance function is on positions.

  • Page 49: Section 9 Spare Parts

    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 1A99993H03 OPM T Signal processor with detector Transceiver board assembly installed. 1A99993H04 Power Supply/Modulator Board-PCB Transceiver 1A99993H06 Zero reflector iris assembly with rotary...
  • Page 50 Transceiver Transceiver protective window kit, 3- screws, 1-150x50mm lens, 1-O-ring, 1-lens retaining ring. 1A99993H42 OPM3000 Control unit s/n 850 up. Control Unit 1A99993H43 OPM4001 Base Control Unit Control Unit Spare/Replacement 1A99993H44 OPM4001 Enhanced Control Unit Control Unit Spare/Replacement 1A99993H45 OPM SD Standard Backup Card...

  • Page 51: Section 10 Drawings

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTION 10 DRAWINGS It is recommended to print drawings with the highest print quality.

  • Page 52: Of 3 - Control Unit To Sensor Wiring /Dual Blower

    I N S T R U C T I O N M A N U A L R E V 4 . 2 OPM6127 1OF3 – CONTROL UNIT TO SENS OR WIRING/DUAL BLOWER...

  • Page 53: Of 3 - Control Unit To Sensor Wiring /Single Blower

    I N S T R U C T I O N M A N U A L R E V 4 . 2 OPM6127 2OF3 – CONTROL UNIT TO SENS OR WIRING /SINGLE BLOWER...

  • Page 54: Of 3 - Control Unit To Sensor Wiring /N O Blower

    I N S T R U C T I O N M A N U A L R E V 4 . 2 OPM6127 3OF3 – CONTROL UNIT TO SENS OR WIRING /NO BLOWER...

  • Page 55: Rs485: Pin Out

    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 ...

  • Page 56: Secton 11 Alarm Matrix

    I N S T R U C T I O N M A N U A L R E V 4 . 2 SECTON 11 ALARM MATRIX High mg High Op AL mg/Op Alarm E.W. Op AL E.W. mg Alarm 011: 012: 0=open, silence O13: O15: 0=...

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