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Emerson OPM4001, Installation And Operation Manual

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Emerson OPM4001 Installation And Operation Manual Download Page 3

 

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

2 

 

Settings Page ............................................................................................................................................................ 20

 

Operator Setup ......................................................................................................................................................... 21

 

Tech Setup and Backup/Restore ................................................................................................................................ 21

 

Set Local Time and Date ............................................................................................................................................ 24

 

Change Passwords .................................................................................................................................................... 26

 

Diagnostics Page ....................................................................................................................................................... 27

 

Alarm Page ............................................................................................................................................................... 28

 

Display Page ............................................................................................................................................................. 29

 

About Page ............................................................................................................................................................... 30

 

SECTION 5 MODBUS AND ANALOG OUTPUTS .................................................................................................................... 31

 

M

ODBUS ADDRESS INFORMATION

 .......................................................................................................................................... 31

 

RS/485

 

C

OMMUNICATIONS AND CONNECTION

 ......................................................................................................................... 33

 

A

LARM RELAY DESCRIPTIONS

 ................................................................................................................................................. 34

 

A

NALOG 

O

UTPUT 

C

ONNECTIONS

............................................................................................................................................ 35

 

Output Channels #1, 2, 3 and 4 .................................................................................................................................. 36

 

4-20

MA

 .......................................................................................................................................................................... 36

 

S

ERVICE MODULE

 ............................................................................................................................................................... 37

 

SECTION 6 CLEAR PATH ADJUSTMENTS ............................................................................................................................. 38

 

Clear on stack zero and span calibration .................................................................................................................... 38

 

Zero reflector adjustment .......................................................................................................................................... 39

 

Span filter value ........................................................................................................................................................ 40

 

Record the zero/span values ...................................................................................................................................... 40

 

Off stack zero calibration ........................................................................................................................................... 40

 

SECTION 7 MICRO-TURN AUDIT KIT ................................................................................................................................... 41

 

U

SING THE ON LINE ZERO REFLECTOR 

(

OPTION

) .......................................................................................................................... 41

 

F

ILTER CORRECTION FORMULA

 ............................................................................................................................................... 42

 

SECTION 8 PREVENTIVE/CORRECTIVE MAINTENANCE ....................................................................................................... 43

 

Preventive/corrective maintenance schedule ............................................................................................................. 43

 

Trouble Shooting ....................................................................................................................................................... 46

 

Trouble shooting -continued ...................................................................................................................................... 47

 

Summary of Contents for OPM4001

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: ...ERATIONS 10 Before start up 10 Environment 10 MOUNTING THE AIR PLENUM AND WEATHER COVERS 11 Transceiver and retro reflector assembly 12 Beam alignment procedure 13 Air flow switch 14 Control unit 14 SECTION 3 BEFORE START UP 15 STACK EXIT CORRELATION COMPUTATION 15 SECTION 4 CONTROL UNIT PAGE DESCRIPTION 16 CONTROL UNIT SCREENS 16 General page layout 16 Control unit Glossary of terms 17 Company in...

Page 3: ...Y DESCRIPTIONS 34 ANALOG OUTPUT CONNECTIONS 35 Output Channels 1 2 3 and 4 36 4 20MA 36 SERVICE MODULE 37 SECTION 6 CLEAR PATH ADJUSTMENTS 38 Clear on stack zero and span calibration 38 Zero reflector adjustment 39 Span filter value 40 Record the zero span values 40 Off stack zero calibration 40 SECTION 7 MICRO TURN AUDIT KIT 41 USING THE ON LINE ZERO REFLECTOR OPTION 41 FILTER CORRECTION FORMULA ...

Page 4: ...9 SPARE PARTS 48 SECTION 10 DRAWINGS 50 OPM6127 1OF3 CONTROL UNIT TO SENSOR WIRING DUAL BLOWER 51 OPM6127 2OF3 CONTROL UNIT TO SENSOR WIRING SINGLE BLOWER 52 OPM6127 3OF3 CONTROL UNIT TO SENSOR WIRING NO BLOWER 53 RS485 Pin out 54 SECTON 11 ALARM MATRIX 55 ...

Page 5: ...RSON 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 POSSIB...

Page 6: ...ment 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 an...

Page 7: ...ge 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 su...

Page 8: ...e 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 increas...

Page 9: ...20 4 to 28 8VDC 10 ripple 20va Alarm Time Delay set point Field programmable Alarm Reset Manual or Automatic Analog Outputs 4 Four 12 bit Analog outputs 4 20mA Field selectable range 5 0 to 100 Ch1 and Ch2 Individually field selectable for Instant opacity or 6 minute average with z s checks or without checks for process control Exit Correlation Lx Lt 0 3 1 0 OPLR Calibration check options Selectab...

Page 10: ...ification Built in through the lens system standard SOURCE Aging Compensation Automatic SOURCE Expected Life 70 000 hours Field proven for 8 years Ambient Temperature Limits 40 to 130 o F 40 to 54 o C Process Gas Up to 750 o 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...

Page 11: ...t to familiarize yourself with the instrument before attempting start up The air purge and Weather cover system Transceiver Retro reflector Service module must be installed and power applied Control unit must be installed and wired to the service module and customers equipment as applicable All wiring and mechanical installations must be complete per drawings provided in this manual All wiring mus...

Page 12: ...actory with the air plenum attached un clip both hold down latches swing open and lift up off the hinge pins Place the Transceiver and retro in a safe place 3 The air plenum is attached to the customer supplied 3 pipe flange by four 2 1 2 long 5 8 11 bolts Working from the 3 flange the correct assembly is gasket then air plenum 4 If you have weather covers remove the two 2 weather cover hood hinge...

Page 13: ...rge 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 ...

Page 14: ...perate Normal Test Normal Opacity T2 Opacity 9 If not already on turn on the power to all air purge systems and service module 10 Align the Reflector mating flange so it is plumb and parallel to the 3 150 mounting flange Use the 3 adjusting nuts on the air purge plenum flange until this is accomplished The adjusting nuts have nylon locking inserts to prevent loosing by vibration 11 Move to the Tra...

Page 15: ... for panel mounting is shown in the drawing section Insert the control unit through the cut out hole Insert the panel mounting hardware in the slots provided on each side of the control unit from the rear Tighten the screws until the control unit is securely held in place Wire the control unit per drawing section and Energized power NOTE CONTROLLER REQUIRES 24VDC 5 7 256 Color Touch panel QVGA TFT...

Page 16: ...or Service module must be installed and power applied Control unit must be installed and wired to the service module and customers equipment as applicable All wiring and mechanical installations must be complete per drawings provided in this manual All wiring must be checked and power applied to both the control unit and the stack maintenance module Beam Alignment procedure has been completed STAC...

Page 17: ...I N S T R U C T I O N M A N U A L R E V 4 2 16 SECTION 4 CONTROL UNIT PAGE DESCRIPTION CONTROL UNIT SCREENS GENERAL PAGE LAYOUT ...

Page 18: ...eset automatically Manual reset means when the high opacity alarm has been activated pushing the return enter button 04 contact will de energize but 02 will remain energized When the level of smoke drops below the alarm point the return enter button is pushed and both 02 04 will be de energised OUTPUT SCALING SETUP Press return enter button to enter Set Ch 1 or 2 to desired opacity range i e for 4...

Page 19: ...mmediately go to the Home page HOME PAGE Touch the icon to go to the sections Calibration Fault Alarms Settings Displays Diagnostics About CLEAN SCREEN To clean the screen press the clean screen icon on the home page green blank page will come in to view with a countdown clock starting at 10 seconds Use appropriate cleaner and cloth to clean this screen When done it will automatically return to th...

Page 20: ...r the fault system Fail will remain in memory until after the values are corrected and another cal is initiated The current opacity and window dust is displayed below for your convenience The system will automatically return to monitoring the process at the 6 minute point from cal start You will know this because the Manual Cal Initiate icon will return to Green It is not necessary to stay in this...

Page 21: ...the Home Touch the Settings icon to get to this page For Operator setup press the button and enter the default password 1111 when indicated and press return arrow For Tech setup press the button and enter the default password 1234 when indicated and press return arrow ...

Page 22: ...values changed All flat buttons are read only The opacity and mg alarms can be turned on or off by touching the appropriate alarm TECH SETUP AND BACKUP RESTORE 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 23: ...external the internal clock is disabled and only an external input will activate the cycle Clone backup restore If not already there Enter SD Password 123 Backup After startup is complete and all controller changes are made enter a new file name with 8 characters and or numbers only no more no less Touch Backup PLC SD System backup all changes to the S D card Restore to restore put the name of you...

Page 24: ...I N S T R U C T I O N M A N U A L R E V 4 2 23 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: ...al time touch and hold any part of the Yellow back ground until Info Mode appears 1 Touch Enter Info Mode at Enter Password page enter 1111 and touch the return button 2 Touch Time Date button 3 Enter the Date dd mm yy 4 Enter the time in 24hr hh mm ss Press ESC until Tech page returns ...

Page 26: ...E V 4 2 25 All raised buttons can be touched and values changed All flat buttons are read only All raised buttons can be touched and values changed Instructions are on the bottom of the screen when required All flat buttons are read only ...

Page 27: ...e tech can reset to default value by holding the reset button for 3 seconds CRITICALLY IMPORTANT THE TECH GATEKEEPER OF THE CONTROL UNIT AT HIS DISCRETION CAN CHANGE BOTH PASSWORDS HOWEVER IT IS CRITICAL THAT THE PASSWORD IS SECURED AGAINST LOSS IF GATEKEEPER S PASSWORD IS LOST CONTACT THE FACTORY FOR PROCEDURE TO RESET TO DEFAULT SETTINGS THIS PROCEEDURE IS IN PLACE TO PROTECT THE INTEGRITY OF TH...

Page 28: ...ls button for control page requires the tech password WARNING pre set returns all selections to default Do not use unless instructed by Rosemount service engineer Touch the Relays button in the sub menu for conditions of the relays to be checked relay is de energized if gray energized if green Touch the Digital in the sub menu button or the right arrow for checking input conditions Inputs are gray...

Page 29: ... E V 4 2 28 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 See Appendix B for alarm relay matrix Auto Manual select ...

Page 30: ...y of interest Pages are 1 Instant Opacity 2 6 minute Average Opacity 3 Split opacity screen Instant Average 4 Dust mg m3 5 Optical Density 6 Op Ave Trend Red Ave Blue Instant 7 Dust Trend Dust max scale can be changed by touching the scale button and entering the F S do not exceed 2000 Set F S here ...

Page 31: ...I N S T R U C T I O N M A N U A L R E V 4 2 30 ABOUT PAGE About page displays the basic setup information ...

Page 32: ...Relay 02 Zero to SM 6 MB 230 Zero not cal 0 in cal 1 Relay 03 Span to SM 3 MB 231 Span not cal 0 in cal 1 Relay 08 DAS in cal 6 MB 232 Zero not cal 0 in cal 1 Relay 09 DAS in Zero 3 MB 233 Zero not cal 0 in cal 1 Relay 10 DAS in span 3 MB 234 Span not cal 0 in cal 1 Relay 11 High alarm Mg MB 235 No alarm 0 Alarm 1 Relay 12 High alarm OP MB 236 No alarm 0 Alarm 1 Relay 13 High alarm Audible OP Mg M...

Page 33: ... 0 Negative Opacity 1 Zero Cal Fail MB 245 Fail 1 Not fail 0 Span Cal Fail MB 246 Fail 1 Not fail 0 No Air flow Modbus only MB 247 OK 0 Not OK 1 Cal cycle MB 248 Off 0 On 1 Read Write Remote Cal Initiate MB 249 Initiate cal 1 Alarm Set point OP MI 235 Format 1 100 Alarm Set point Mg MI 236 5000 500 Alarm delay MI 237 Format 1 360 seconds Early Warning Set point OP MI 238 Format 1 MI 236 Early Warn...

Page 34: ...in length Belden P N 3106A cable is recommended Note Cable drawing and pin out at the end of drawing section If not specified in the original order default is as follows NOTE The following communication parameters cannot be changed in the field the controller must be returned to the factory Baud Rate 9600 Data Bits 8 Parity None Flow Ctrl None Timeout 0 2 seconds ...

Page 35: ...ther commons on the controller OPM4001 ENHANCED Relays Group 1 Relays Zero solenoid to SM 02 Span solenoid to SM 03 Group 2 Relays In CAL to DAS 6 Minutes 08 Zero solenoid command contact 3 Minutes 09 Span solenoid command contact 3 Minutes 10 High mg Alarm 11 High Opacity Alarm 12 High Opacity mg Alarm Silence 13 Fault relay Normal 0 Fault on When 1 14 Early warning Hi mg 15 Early warning Opacity...

Page 36: ...I N S T R U C T I O N M A N U A L R E V 4 2 35 ANALOG OUTPUT CONNECTIONS ...

Page 37: ... output CH4 Aout3 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 Channel 1 Is dedicated to the Service Module display with F S 5 to 99 9 opacity Channel 2 3 and 4 can be used for DAS recorder etc To utiliz...

Page 38: ...ems response to zero opacity Energize in conjunction with the span filter to observe the upscale span opacity calibration point OPERATE SPAN This switch controls the span filter solenoid In the operate position the span filter is not in the measuring path and is considered normal operation When the span filter solenoid is energized the span filter is placed in the measurement path and is considere...

Page 39: ...nts are on the 222 1667 PC Board p n 1A99993H03 for replacement 6 Adjust the 20 turn Zero potentiometer on board 222 1667 p n 1A99993H03 for replacement marked PT 1 CW for an upscale reading 15 then slowly CCW for 0 1 opacity 7 Install the Micro turn 200 on line test reflector on the transceiver and screw the device to the transceiver with the mounting screw With the thumbwheel adjust the on line ...

Page 40: ...rn the mirror to normal resting position by returning the zero switch to operate position 4 If required insert a 1 16 Allen wrench into the adjustment set screw located on the top of the zero reflector Turn the set screw clock wise 1 8 turn 5 Remove the Allen wrench and initiate a zero utilizing the zero switch on the service module and after 15 seconds observe the reading is moving toward the des...

Page 41: ...tack condition is not possible and the zero appears to be incorrect or if the flange to flange distance on site are different than the original factory set up Remove the transceiver and retro reflector from the hinge pins remove the service module and install the system on OPM Opacity portable off stack test stands 1A99993H37 and at the correct flange to flange distance plus 11 inches The addition...

Page 42: ... you re calibrate Neutral Density Filters used for Opacity Audits at the minimum of 6 months Filters are tested per USA Code of Federal Regulations 40CFR60 Appx B Performance Specification 1 Section 7 1 3 Attenuation Calibration Filter certification Neutral Density Filters for Micro turn 200 are calibrated on a Perkin Elmer Lambda Series 6 PECSS Spectrophotometer per Federal Environmental Protecti...

Page 43: ...lides will read differently To calculate what the slide will read with another OPLR use the formula 2 100 100 1 1 1 5 0 2 OP Op M 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 5 54 100 100 1 23 1 1 5 0 5 1 ...

Page 44: ...k alignment correct if necessary Check air filters replace if necessary Quarterly All daily and monthly checks Perform COM Audit per EPA regulation 40 CFR 60 App B PS 1 Replace air filters 8 pack 1A99993H09 Check all air hoses and clamps for tightness and wear correct as necessary Check weather cover gaskets for leakage Check all bolts for tightness Check all electrical connections are secure Chec...

Page 45: ...orrect 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 re...

Page 46: ...Avoid using abrasive cleaners as they will scratch the housing and front panel Interior Dust in the interior of the control unit should be removed before it builds up enough to cause arcing and short circuits during periods of high humidity Dust is best removed from the interior by the type of canned air used for computer cleaning Dirt clinging to the surfaces can be removed with a soft paintbrush...

Page 47: ...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 z...

Page 48: ...e 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 ...

Page 49: ...r 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 ...

Page 50: ...y 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 O ring 1 lens retaining ring X Transceiver 1A99993H42 OPM3000 Control unit s n 850 up Control Unit 1A99993H43 OPM4001 Base Control Unit Spare Replacement X Control Unit 1A99993H44 OPM4001 Enhanced Control Un...

Page 51: ...I N S T R U C T I O N M A N U A L R E V 4 2 50 SECTION 10 DRAWINGS It is recommended to print drawings with the highest print quality ...

Page 52: ...I N S T R U C T I O N M A N U A L R E V 4 2 51 OPM6127 1OF3 CONTROL UNIT TO SENSOR WIRING DUAL BLOWER ...

Page 53: ...I N S T R U C T I O N M A N U A L R E V 4 2 52 OPM6127 2OF3 CONTROL UNIT TO SENSOR WIRING SINGLE BLOWER ...

Page 54: ...I N S T R U C T I O N M A N U A L R E V 4 2 53 OPM6127 3OF3 CONTROL UNIT TO SENSOR WIRING NO BLOWER ...

Page 55: ...l 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 t...

Page 56: ...High set points 0 0 0 0 0 set point after delays satisfied AL 1 1 1 1 1 set point EW Reset button pushed 1 1 1 1 1 set point Process Alarm Reset button pushed 1 1 0 1 1 Return to 0 0 0 0 0 0 Manual alarm reset after returning to zero Start 0 use test value above High set points 0 0 0 0 0 set point after delays satisfied AL 1 1 1 1 1 Return to 0 1 1 1 1 1 Process Alarm reset button pushed 0 0 0 1 1...

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