Emerson Rosemount OPM4001 Opacity/Dust Density Monitor Installation and Operation Manual

Instruction Manual 2.1 OPM4001 Opacity/Dust Density Monitor Installation and Operation Manual Page | 1 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 Page | 2 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 Page | 3 Instruction Manual 2.1 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 e-mail: GAS.CSC@emerson.com 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. Page | 4 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 Page | 5 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. 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. Page | 6 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. Page | 7 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 + 122 o 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. Page | 8 Instruction Manual 2.1 OPM4001 Specifications: 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 Ch1 andOPLR Ch2 Individually field selectable for Instant % opacity, or 6 minute average with z/s checks or without Selectable internal control. timed or computer initiates or push checks for process button on demand. Calibration check options Communication Remote access, RS485 MODBUS networking. Battery Backup 7 years typical Page | 9 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: Angle of View 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. < 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 Peak and Mean Spectral Response Page | 10 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%. Page | 11 Instruction Manual 2.1 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. Lx OPLR  2 * Lt 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. OPLR  120  0.50 2 *120 Page | 12 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. Page | 13 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 installed vertically plumb. be 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: 1-800-433-6076 or 1-440914-1261 E-mail: GAS.CSC@emerson.com 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. Page | 14 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. Page | 15 Instruction Manual 2.1 Flange to stack installation Page | 16 Instruction Manual 2.1 Air purge/Weather cover mechanical Installation Page | 17 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. Page | 18 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! Page | 19 Instruction Manual 2.1 Section 3 Remote Control Unit (RCU) operation Page Description RCU buttons About page 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. Page | 20 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 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). Page | 21 to enter the 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: 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) Worcester Polytechnic Institute 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 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. Page | 22 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. Page | 23 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. Page | 24 Instruction Manual 2.1 Scrolling multiple main display pages Pressing ESC will get you back to the selection page, scroll to OPM4001 Display and press return/enter button will be displayed: the process opacity display page 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. Page | 25 Instruction Manual 2.1 Password protected parameters 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. Page | 26 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 Section 4 Modbus Modbus Setup 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. Modbus Write Write: Remote Cal. Initiate MB 51 Initiate cal =1 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 In maintenance Page | 28 Instruction Manual 2.1 Modbus Read 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: 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 2221667 (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 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: M2       Op1  0.5      *100  OP2 1   1     100       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? 1.5       23.1  0.5   1   1  100    *100  54.5%        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: 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) Worcester Polytechnic Institute 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 World Wide Web: www.raihome.com Warnings and Safety Guidelines for user safety and equipment protection Page | 44 Instruction Manual 2.1 Trouble Shooting 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 Operate/test switch must be in to the control unit is open 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 1- Reference voltage TP-2 high opacity or erratic in normal, zero & on signal processor 1667 span mode, service module meter in opacity is lower than 9.3V reads high or erratic. 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 1- Correct process 2- Alignment is out 2- Adjust alignment until centered on target. High dust alarm and /or cal fail cal message Transceiver window Clean window and or zero mirror and/or zero mirror is dirty 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 Page | 45 Check power, check SM fuse. Replace as needed Instruction Manual 2.1 Trouble shooting -continued Problem Possible Cause Remedy Maintenance Mode message Maintenance switch or maintenance function is on Return all positions. to operate 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 Control unit blank Control unit fuse open Page | 46 Replace and check for shorts in the power supply or individual boards. Instruction Manual 2.1 Section 9 Spare parts 1A99993H03 OPM T Signal processor with detector board assembly installed. X Transceiver 1A99993H04 Power Supply/Modulator BoardPCB Zero reflector iris assembly with rotary solenoid, reflector tape and zero arm for Opacity Transceiver . X 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 1A99993H06 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 OPM3000/4000 Series Air Plenum Assembly (with lift-off hinge), opacity fits either Transceiver or Retro. X Transceiver Retro reflector 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 OPM SD Standard Backup Card (2GB) OPM4000 Series Service Module Zero-Span controller main PC board. X Control Unit X Control Unit X Control Unit 1A99993H40 1A99993H45 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